Method of forming a butter/margarine blend

ABSTRACT

A method of forming a butter/margarine blend that includes removing water of butterfat from a feed material that includes butter to yield an intermediate, combining a non-dairy fat with the intermediate to form an intermediate blend, and processing the intermediate blend to form the butter/margarine blend.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority from

(1) U.S. Provisional Patent Application Ser. No. 60/160,111 that wasfiled on Oct. 18, 1999,

(2) U.S. Provisional Patent Application Ser. No. 60/160,115 that wasfiled on Oct. 18, 1999,

(3) PCT International Application Number PCT/US00/41263 that was filedon Oct. 18,2000, and

(4) PCT International Application Number PCT/US00/41264 that was filedon Oct. 18, 2000.

BACKGROUND OF THE INVENTION

The present invention generally relates to a method of formingbutter-based products, such as a butter/margarine blend, and tobutter-based products that are prepared by this method. Morespecifically, the present invention relates to a method of concentratinginterfacial butter solids of butter, to a method of incorporating theinterfacial butter solids in butter-based products, and to butter-basedproducts that contain a concentrated amount of the interfacial buttersolids.

Butter preparation methods represent some of the oldest techniques forutilizing fat components that are found in milk. Butter manufacture hasbeen accomplished in one form or another for over 4500 years. Over thecenturies, butter has been used in sacrificial worship ceremonies, formedicinal and cosmetic purposes, and as a human food.

Butter production techniques generally evolved into more sophisticatedtechniques as new forms and uses of equipment developed. For example,the barrel churn made its appearance toward the end of the 18th centurywhen non-wooden manufacturing materials entered widespread use increaming and butter making equipment. These advances led to advances incream separation techniques and, by 1879, continuous operation creamseparators were known in Sweden, Denmark, and Germany. Likewise, butterproduction evolved from an individual farm activity to a factory basedtechnique with the introduction of milk pooling systems for creameryoperation in the 1870s. Later advances in fat quantification techniques,pasteurization, refrigeration, and bacterial culture usage furtheradvanced the art of butter production.

Advances in butter production technology helped make butter a stapleitem in the kitchen. Certain components of butter, such as interfacialbutter solids, give butter-based baked goods properties that are notachievable by margarines and presently available butter/margarineblends. For example, butter melts somewhat evenly in the mouth to yielda smooth, rich mouth-feel that is characteristic of butter. As anotherexample, the protein and lactose components of butter give desirablebrowning characteristics to baked goods that incorporate butter. Also,the phospholipid portion of butter gives body to baked goods and givesthe baked goods the characteristic rich flavor long associated withbutter. Phospholipids, proteins, and sugars, such as lactose, are eachcomponents of interfacial butter solids.

Despite these highly desirable taste and baking properties associatedwith butter, butter consumption came under attack by nutritionists andthe medical profession during the 1970s and 1980s because of linksthought to exist between butter consumption and certain healthconditions. Also, butter prices tend to be relatively volatile over thelong term. These factors led to increasing use of butter substitutes,such as margarine and butter/margarine blends, that included fat sourcesin addition to, or other than, butterfat. Existing butter/margarineblends are typically based on butter; other fat sources, such as soybeanoil, cotton seed oil, canola oil, and other types of vegetable oils;water; and emulsifying agents, such as monoglycerides and diglycerides.Margarines are typically based on various combinations of water andvegetable oils and may include or exclude butterfat, depending upon theformulation of the particular margarine.

However, even present margarines that include butterfat and presentbutter/margarine blends that include butter do not have thecharacteristic mouth-feel of butter and typically do not give bakedgoods the browning properties and body-yielding properties that arecharacteristic of butter. This is true even though numerous artificialbutter flavoring compounds have been developed and incorporated intomargarines and butter/margarine blends over the years.

Thus, even though these alternatives to pure butter have helped toreduce the amount of saturated fats and calories in the human diet andhave helped to stabilize the cost of supplying nutritionally necessaryfat in the human diet, these advances have come at the cost of losingbutter-like baking properties, such as the browning and bakingcharacteristics yielded by butter, and the rich flavor andcharacteristic mouth-feel exhibited by butter. Thus, consumers,including household consumers and commercial baking concerns alike, longfor an improved butter/margarine blend that accommodates health concernsabout butterfat while achieving baking properties, mouth-feelproperties, and flavor and taste that equal or even exceed thoseexhibited by butter.

BRIEF SUMMARY OF THE INVENTION

The present invention concerns a method of forming a butter-basedproduct, such as a butter/margarine blend, that includes removing wateror butterfat from a feed material that includes butter to yield anintermediate, combining a non-dairy fat with the intermediate to form anintermediate blend, and processing the intermediate blend to form thebutter-based product. The present invention further includes a method offorming a concentrated butter. The method of the present inventionadditionally includes a concentrated butter, a butter-based product, anda concentrated butter product.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE is a schematic of a process for producing a butter-basedproduct, such as a butter/margarine blend, in accordance with thepresent invention.

DETAILED DESCRIPTION

The present invention generally relates to a method of formingbutter-based products, such as a butter/margarine blend, and tobutter-based products that are prepared by this method. Morespecifically, the present invention relates to a method of concentratinginterfacial butter solids of butter, to a method of incorporating theinterfacial butter solids in butter-based products, and to butter-basedproducts that contain a concentrated amount of the interfacial buttersolids.

A process for preparing the butter-based product, such as thebutter/margarine blend, of the present invention is generally depictedat 10 in the FIGURE. First, a feed material 12, such as butter or amixture of butter and one or more additional components, is heated usinga heat exchange mechanism 14, such as a steam-jacketed pipe, to form aliquid feed material 16, such as melted butter or a liquid compositioncontaining melted butter, and thereby remove all crystallization memoryof the butter. The liquid feed material 16 is placed in an agitated andheated tank 18. Mixed liquid feed material 20 is then transferred fromthe tank 18 to an evaporator 22 to concentrate the mixed liquid feedmaterial 20 by removing water 24 from the mixed liquid feed material 20under controlled vacuum and temperature conditions.

A reduced water-content material 26 that is derived in the evaporator 22is then transferred to a separator 28 and separated into butterfat 30,byproduct butterfat 31, and a butter solids intermediate 32. Thebyproduct butterfat 31 exits the process 10 for further processing orfor sale to customers as butterfat The ratio of butterfat removed fromthe process 10 as byproduct butterfat 31 versus butterfat remaining inthe process 10 as the butterfat 30 may be adjusted to provide productsproduced using the process 10 with different butterfat contents andconcentrations. As an alternative to removing the byproduct butterfat 31directly from the separator 28, excess butterfat beyond the butterfatrequired to produce the butter-based products of the present inventionmay be removed from the process 10 by removing byproduct butterfat fromthe butterfat 30 after separation of the butterfat 30 and the buttersolids intermediate 32 in the separator 28.

The butterfat 30 is placed into a holding tank 34.and the butter solidsintermediate 32 is placed into a holding tank 36. If any byproductbutterfat is removed from the butterfat 30, the byproduct butterfatremoval may occur either before or after the butterfat 30 has beenplaced in the holding tank 34. The holding tank 34 and/or the holdingtank 36 may be heated, as necessary, to maintain the butterfat 30 as aliquid and/or to maintain the butter solids intermediate 32 as a liquid.Additionally, the tanks 34, 36 may be agitated to maintain thehomogeneity of the butterfat 30 and the homogeneity of the butter solidsintermediate 32, respectively. The composition of the butterfat 30 maybe left unchanged in the holding tank 34, and the composition of thebutter solids intermediate 32 may be left unchanged in the holding tank36.

On the other hand, an emulsifying agent may optionally be added to thetank 34 and thereafter may be dispersed within the butterfat 30. Theratio of emulsifying agent to butterfat 30 in the tank 34 may beselectively adjusted to attain desired properties in butter-basedproducts, such as the butter-margarine blend, that may be produced usingthe process 10. Likewise, food grade salt may optionally be added to thetank 36 and thereafter may be dispersed within the butter solidsintermediate 32. The ratio of salt to butter solids intermediate 32 inthe tank 36 may be selectively adjusted to attain desired properties inbutter-based products, such as the butter-margarine blend, that may beproduced using the process 10.

The butterfat 30 is metered from the holding tank 34 as butterfat 38into a weigh and mix tank 42, and the butter solids intermediate 32 ismetered from the holding tank 36 as butter solids intermediate 40 to theweigh and mix tank 42. Non-dairy fat 44, such as vegetable oil, mayoptionally also be metered into the weigh and mix tank 42. The ratio ofbutterfat 38 to butter solids intermediate 40 to non-dairy fat 44 in theweigh and mix tank 42 may be selectively adjusted to attain desiredproperties in butter and butter-based products produced using theprocess 10. The butterfat 38, the butter solids intermediate 40, and thenon-airy fat 44 are mixed together in the weigh and mix tank 42 to forma water-in-fat dispersion, namely an intermediate blend 46.

The intermediate blend 46 along with optional additive(s) 48 arecombined, blended, and agitated in a blend tank 50 to form a liquidbutter/margarine blend 52. The liquid butter/margarine blend 52 may thenbe conventionally processed in traditional margarine and buttercrystallization equipment, such as a chill roller or a swept surfaceheater exchanger 54, to form a solidified butter/margarine blend 56. Thesolidified butter/margarine blend 56 may be packaged in conventionalbutter and margarine packing equipment, such as a packing unit 58, toyield a packaged butter/margarine product 60.

The butter-based product that exits the blend tank 50 is subsequentlyreferred to primarily in terms of the butter/margarine blend 52.Nonetheless, it is to be understood that the butter-based products thatexit the tank 42 and the tank 52, along with any derivatives of thesebutter-based products, may alternatively be butter, a reduced-fatbutter, a butter-based spread, or any other water-in-fat dispersion thatincludes interfacial butter solids from the butter of the feed material12 and may also include some water and/or butterfat from the butter ofthe feed material 12.

In the process 10, the feed material 12 may be or may include anybutter. As used herein, all references to “butter” are to be understoodas referring to a dairy product prepared by churning, or equivalentlyprocessing, milk, cream, or a combination of milk and cream, thoughother optional ingredients beyond milk and/or cream may optionally beincluded before, during and/or after the butter production. The churningor equivalent processing may be accomplished in either batch-wise orcontinuous fashion. The source of the milk and/or cream that is used toform the butter may be bovine, ovine, caprine, or the like. The butterthat makes up some or all of the feed material 12 may generally take anyform, such as semi-solid, pumpable butter that exits the churningprocess; chilled solid butter; or butter that has been melted to formliquid butter.

Non dairy ingredients, preferably other minor non-dairy ingredients,such as salt, a coloring agent, and/or vitamins, may optionally beincluded in the milk and/or cream that is churned to form the butter ormay optionally be added to the milk and/or cream during the churningprocess. Preferably, however, salt, if added, is added at the tank 36,and other minor non-dairy ingredients, such as vitamins, lactic acid,and/or the coloring agent, are added at the blend tank 50 to simplifyoperational considerations for the evaporator 22 and the separator 28.

Non-dairy fat may also optionally be added to the milk and/or cream thatis processed to form the butter or may be added to the milk and/or creamduring the butter production process. Non-dairy fat is preferably notadded to the milk and/or cream either before or during processing of themilk and/or cream to form the butter, since some of any such addednon-dairy fat would likely be present in the butter milk byproduct ofthe butter forming process and would reduce the value of the byproductbutter milk. Also, non-dairy fat is preferably not added to the milkand/or cream either before or during processing of the milk and/or creamto form the butter, since any such addition of non-dairy fat wouldprevent the butter being formed from being labeled as butter, and wouldprevent butter-based products that exit the tank 42 and the tank 52,along with any derivatives of these butter-based products, from beinglabeled as butter-based products, such as the butter/margarine blend,under the present dietary labeling standards of United States regulatoryauthorities, such as the U.S. Department of Agriculture (U.S.D.A.).

Churning of milk and/or cream initially causes fractionation of the milkand/or cream into (1) an aqueous phase that yields a butter milkbyproduct and (2) a fat phase that includes milk fat globules. Thechurning process also causes aggregation of milk fat globules that, withthe aid of various interfacial butter solids such as phospholipids,entrap water molecules from the aqueous phase to form the water-in-fatdispersion that predominantly or exclusively exists in butter. It isbelieved that the water-in-fat dispersion of butter is not a trueemulsion, but instead represents a surface absorption phenomena in whichwater is absorbed within a matrix of milk fat globules. Additionally, itis believed that the solids leaving as part of the aqueous butter milkbyproduct of the churning process are qualitatively different in naturethan the solids remaining in the butter produced by churning, since thetaste of this aqueous butter milk byproduct is qualitatively quitedifferent from the taste of the aqueous layer resulting when butter ismelted and stratified into a fat layer and an aqueous layer.

Unless otherwise indicated, all references to “interfacial buttersolids” are to be understood as referring to the solid particles and/orsemi-solid particles that tend to congregate proximate the interface ofthe aqueous phase and the fat phase of melted butter (1) when thetemperature of the melted butter is in the range of about 80° F. (about26.7° C.) to about 145° F. (about 62.8° C.) and (2) when the aqueousphase and the fat phase are permitted to separate under the influence ofgravity or when the aqueous phase and the fat phase are forced toseparate, such as by processing the melted butter in a centrifuge. Somecomponents of the “interfacial butter solids”, such as proteins andsugars, tend to exist in the aqueous phase of the melted butterproximate the interface, while other components of the “interfacialbutter solids”, such as phospholipids, tend to exist proximate theinterface of the fat phase and the aqueous phase of the melted butter inboth the fat phase and the aqueous phase of the melted butter.

Consequently, the “interfacial butter solids” includes those solidparticles and/or semi-solid particles that tend to congregate proximatethe interface of the aqueous phase and the fat phase of the meltedbutter under the influence of gravity or physical separation, no matterwhether those solid particles and/or semi-solid particles are in theaqueous phase, the liquid phase, or both the aqueous phase and theliquid phase of the melted butter. Additionally, solid particles and/orsemi-solid particles of the interfacial butter solids may be dissolved(solubilized) in the aqueous phase and/or the fat phase of the meltedbutter.

The term “interfacial butter solids” includes all solid particles and/orsemi-solid particles that tend to congregate proximate the interface ofthe aqueous phase and fat phase of melted butter, rather than only solidparticles and/or semi-solid particles that actually have congregatedproximate the interface of the aqueous phase and the fat phase of meltedbutter. The term “interfacial butter solids” excludes any non-dairyadditives, such as salt, that are added to the milk and/or cream that isprocessed to form the butter and also excludes any non-dairy additivesthat are added to the milk and/or cream during the butter productionprocess or that are added to the butter after the butter productionprocess. The term “interfacial butter solids” also excludes anynon-dairy fat that is added to the milk and/or cream that is processedto form the butter, any non-dairy fat that is added to the milk and/orcream during the butter production process, and any non-dairy fat thatis added to the butter after the butter production process.Additionally, unless otherwise-indicated, the term “non-dairy” means nota dairy material and not derived from a dairy material. Milk cream,whey, cheese, and butter are some non-exhaustive examples of dairymaterials.

As noted, some components of the “interfacial butter solids”, such asproteins and sugars, tend to exist in the aqueous phase of the meltedbutter proximate the interface. Therefore, these protein and sugarcomponents of the interfacial butter solids will predominantly, if notnearly exclusively, remain in the aqueous phase upon separation of theaqueous phase from the melted butter. Also as noted, other components ofthe “interfacial butter solids”, such as phospholipids, tend to existproximate the interface of the fat phase and the aqueous phase of themelted butter with part of each phospholipid molecule typically locatedin the aqueous phase of the melted butter and with another part of eachphospholipid molecule typically located in the fat phase of the meltedbutter. Nonetheless, upon removal of the aqueous phase from meltedbutter, most, if not essentially all, of the phospholipids tend to staywith the aqueous phase; this tendency of the phospholipids to stay withthe aqueous phase instead of with the fat phase upon removal of theaqueous phase from the melted butter is believed to occur because theattraction of each phospholipid molecule portion present in the aqueousphase to the aqueous phase tends to be stronger than the attraction ofeach corresponding phospholipid molecule portion present in the fatphase is to the fat phase. Despite this observation, when separating theaqueous phase and the fat phase of the reduced water content material 26into the butterfat 30, the byproduct butterfat 31, and the butter solidsintermediate 32, some butterfat may be allowed to stay with the aqueousphase (butter solids intermediate 32) to maximize the amount of thephospholipid component of the interfacial butter solids that remains inthe butter solids intermediate 32.

Additionally, unless otherwise indicated, all references to “butterfat”are to be understood as referring to dairy (milk) fat that is both (1)present in butter and (2) present in the liquid dairy material, such asmilk, cream, or combination of milk and cream, that is processed to formthe butter. Consequently, unless otherwise indicated, the term“butterfat” excludes non-dairy fats, including, but not limited to, anynon-dairy fat that is added to, or as, feed components of the butterproduction process; any non-dairy fat that is added to the butterproduction process during butter manufacture; and any non-dairy fat thatis added to the butter after the butter production process.

The feed material 12 preferably contains, and more preferably consistsof, butter that is recognized as butter in the United States byregulatory authorities, such as the Department of Agriculture (U.S.D.A).The U.S.D.A. defines butter as follows:

The food product usually known as butter, and which is made exclusivelyfrom milk or cream, or both, with or without additional coloring matter,and containing not less than 80 percent by weight of milkfat, alltolerances having been allowed for.

7 C.P.R §58.305(a), revised Jan. 1, 1997. Generally, however, the feedmaterial 12 may contain or may consist of any butter, such as butterformed by churning. This means that butter present in the feed material12 will typically have a butterfat concentration of at least about 60weight percent, based on the total weight of the butter leaving thebutter production process, since the aggregation of milk fat moleculesinto the “butterfat” matrix that entraps water molecules will typicallynot form if the milk fat concentration of the in-process dairy materialthat is transformed into butter is less than about 60 weight percent,based on the total weight of the in-process dairy material.

For purposes of marketing the butter solids intermediate 32 (asconcentrated liquid butter), the intermediate blend 46, (he liquidbutter/margarine blend 52, and/or the solidified butter/margarine blend56 to American consumers, the butter that forms, or is part of, the feedmaterial 12 is preferably based upon dairy material that is produced byor derived from dairy cattle in the United States, since the palates ofAmerican consumers are accustomed to dairy material that is produced byor derived from dairy cattle in the United States. Dairy animals, suchas dairy cattle, in other regions of the world are often fed or grazedupon different feeds than dairy cattle in the United States. Forexample, dairy cattle in New Zealand are typically grazed on cloverwhich gives butter a unique flavor that is typically not appreciated byAmerican consumers.

For purposes of marketing the butter solids intermediate 32 (asconcentrated liquid butter), the intermediate blend 46, the liquidbutter/margarine blend 52, and/or the solidified butter/margarine blend56 to consumers in countries other than the United States, the butterthat forms, or is part of, the feed material 12 may be based upon dairymaterial that is produced by or derived from dairy cattle in countriesother than the United States, while realizing that consumers in aparticular country will typically prefer dairy products that are basedupon dairy material produced by or derived from dairy cattle in thatparticular country.

The time between formation of the butter and introduction of the butterinto the process 10 as the feed material 12 or as a component of thefeed material 12 is preferably minimized to maximize the “fresh churned”butter taste of products produced in accordance with the presentinvention. Though not wishing to be bound by theory, it is believed thatair entrained in butter during the churning process causes orcontributes to degradation of flavor components in freshly-churnedbutter that are responsible for the difference between the taste offreshly churned butter and the taste of butter that can no longer beconsidered to be fresh churned.

Therefore, the butter that forms, or is part of, the feed material 12 ispreferably freshly churned butter that has been produced no more thanabout 8 hours prior to being incorporated in the process 10. In oneparticularly preferred embodiment, the butter that forms, or is part of,the feed material 12 is introduced into the process 10 in semi-solidform directly from the churning process to minimize the time betweenformation of the butter and feeding of the butter to the process to asthe feed material 12 or as a component of the feed material 12.

Additionally, in the process 10, the feed material 12, the liquid feedmaterial 16, the mixed liquid feed material 20, the reducedwater-content material 26, the butterfat 30, the byproduct butterfat 31,the butter solids intermediate 32, the intermediate blend 46, the liquidbutter/margarine blend 52, the solidified butter/margarine blend 56, thepackaged butter/margarine blend 60, and derivatives of any of these areeach preferably handled carefully in the process 10 to minimize damageto these streams or to any components of these streams. Careful handlingentails minimizing, and preferably eliminating, exposure of thesestreams to temperatures above about 160° F. (above about 71.1° C.).Though the mixed liquid feed material 20 may be exposed to a temperatureof about 200° F. (about 93.3° C.) to about 210° F. (about 98.9° C.)prior to and immediately after entering the evaporator 22, this hightemperature exposure is brief, since the material 20 rapidly cools toapproximately 140° F. (approximately 60° C.), or less, soon afterentering the evaporator 22. Also, all processing and handling of thesestreams in the process 10 is preferably done under conditions thatminimize the potential for oxidation of these streams, or of componentsof these streams, such as by blanketing these streams with an inert gas,such as nitrogen. Furthermore, transfer of these streams within theprocess 10 is preferably accomplished using a positive displacementpump, such as a lobe-type pump or a high pressure piston pump of thetype typically used in dairy homogenizers.

Although the feed material 12 preferably consists of only butter, thefeed material 12 may permissibly include one or more other materials inaddition to butter. When other material(s) in addition to butter areincluded in the feed material 12, the concentration of butter in thefeed material 12 is preferably at least about 50 weight percent, morepreferably at least about 75 weight percent, and still more preferablyat least about 90 weight percent, based on the total weight of the feedmaterial 12. Butter is preferably the major, more preferably thepredominant, and most preferably the only component of the feed material12, since the interfacial butter solids that are present in butter andthat are concentrated in accordance with the present invention providethe desirable, enhanced baking, flavor, and mouth-feel properties thatare achieved in products that are produced in accordance with thepresent invention.

Nonetheless, in place of some or all of the butter, the feed material 12may optionally include any butter material that is derived from butter,so long as the butter material includes interfacial butler solids. Inaddition to interfacial butter solids, the optional butter material mayoptionally also include butterfat, water, or any combination of waterand butterfat in any concentration. Also, in addition to butter and theoptional butter material, the feed material 12 may permissibly, thoughpreferably does not, include any edible non-dairy fat, such as lard,beef tallow, vegetable oil, and/or shortening; water, any food gradecoloring agent(s); any food grade emulsifying agent(s) such as lecithin,a monoglyceride, or a diglyceride; or any combination of any of these.Added food grade emulsifying agent(s) are preferably not included withthe butter in the feed material 12, since the presence of added foodgrade emulsifying agents in the feed material 12, under some operatingconditions, may complicate removal of water via the evaporator 22 and/orseparation of the butterfat 30 and byproduct butterfat 31 from thebutter solids intermediate 32 in the separator 28.

If the optional butter material is included in the feed material 12, theinterfacial butter solids concentration in the butter material ispreferably about the same as the concentration of interfacial buttersolids in the butter that is used as part of the feed material 12. Thispreference is based upon the fact that centrifugal separation equipmentthat may be used as the separator 28, at some operating conditions, hasbeen found to sometimes lose some amount of interfacial butter solidduring U.S.D.A. mandated “burping” of the centrifugal separationequipment. It is believed that the interfacial butter solids losses fromthe centrifugal separator will tend to increase, as a percentage of thetotal interfacial butter solids in the feed material 12, as theconcentration of interfacial butter solids increases in the feedmaterial 12. Thus, while it is entirely desirable to have interfacialbutter solids in the feed material 12, the concentration of interfacialbutter solids included in the optional butter material is preferablyabout the same as the concentration of interfacial butter solids in thebutter of the feed material 12 to avoid enhancing the relative amount ofinterfacial butter solids lost due to U.S.D.A.-mandated burping of anycentrifugal separator that is used as the separator 28.

Likewise, the content of solids other than interfacial butter solids inthe feed material 12 is preferably minimized to minimize loss ofinterfacial butter solids during the U.S.D.A.-mandated burping of anycentrifugal separator used as the separator 28. For this reason, and tominimize the potential for corrosion in the evaporator 22, the butterthat is used in or as the feed material 12 is preferably unsaltedbutter, since any desired salt may be added later in the process 10 tothe tank 36.

Furthermore, the feed material 12 preferably does not include any ediblenon-dairy fat, since addition of non-dairy fat as part of the feedmaterial 12 would increase the expense and the amount of work needed toconcentrate the interfacial butter solids using the evaporator 22 andthe separator 28. Also, any non-dairy fat added as part of the feedmaterial 12 would diminish the market value of any byproduct butterfat31 and any butterfat 30 that is removed from the holding tank 24 asby-product, rather than being used as butterfat 38 that is added to thetank 42. Likewise, the feed material 12 preferably does not include anyadded water beyond water present in the aqueous phase of butter, sinceaddition of extra water as part of the feed material 12 would alsoincrease the expense and the amount of work needed to concentrate theinterfacial butter solids using the evaporator 22.

Additionally, the feed material 12 preferably does not include any foodgrade emulsifying agent(s), since it has been found that the interfacialbutter solids from the feed material 12 typically supply most, if notall, of the blending power necessary to form a stable water-in-fatmatrix in the concentrated liquid butter, the intermediate blend 46, theliquid butter/margarine blend 52, and the solidified butter/margarineblend 56 that may be produced in accordance with the present invention.This observation about the interfacial butter solids from the feedmaterial 12 typically supplying most, if not all, of the blending powernecessary to form a stable water-in-fat matrix depends upon at least thefollowing factors: (1) the concentrations of interfacial butter solidsin the butterfat 38 and in the butter solids intermediate 40, (2) theratio of the butterfat 38, the butter solids intermediate 40, and theoptional non-dairy fat 44 to each other in the intermediate blend 46,(3) the nature of the non-dairy fat 44, (4) the fat profile of thebutterfat 38 or of the blend of the butterfat 38 and any optionalnon-dry fat 44 and (5) mixing conditions (such as mixing severity andcomponent temperatures) in the tank 42. Ultimately, food gradeemulsifying agent(s) are preferably not added during processing of thefeed material 12, and derivatives thereof, in accordance with thepresent invention, such as in the process 10, though it is neverthelesspermissible to include emulsifying agent(s) as an additive to thebutterfat 30 in the tank 34 or as a component of the additive(s) 48.

The tank 18 in the process 10 functions as an accumulation tank for theliquid feed material 16 and balances differences between the flow rateof the feed material 12 and the flow rate of the mixed liquid feedmaterial 20. When the tank 18 is included in the process 10, the liquidfeed material 16 is subjected to mild agitation, only, in the tank 18that is sufficient to prevent stratification of components of the liquidfeed material 16 and thereby avoid significant variations in thecomposition of the mixed liquid feed material 20 that is sent to theevaporator 22. As yet another alterative, the tank 18 may be left out ofthe process 10 in favor of a balance tank for the feed material 12,prior to heating of the feed material 12.

Preferably, however, the feed material 12 balance tank or the tank 18 isincluded to provide an option of returning a portion of thereduced-water content material 26, a portion of the butterfat 30, and/ora portion of the byproduct butterfat 31 to the feed material 12 balancetank or the tank 18 for subsequent reflux in the evaporator 22 toenhance flavor development in the light butter 62. As discussed morefully below, it is believed that hydrolytic and/or hydrolysis reactionsoccurring during reflux contact between the butterfat and aqueouscomponents in the evaporator 22 may enhance flavor development in theliquid butter/margarine blend 52 and derivatives thereof.

The evaporator 22 may be or include any type of evaporation equipment,such as a vacuum can, a triple effect evaporator, a vacuum distillationtower, or any combination of any of these, that is capable of removingwater 24 from the mixed liquid feed material 20. Preferably, theevaporator 22 allows components that are present in the mixed liquidfeed material 20 to quickly cool to about 140° F., or less, soon afterthese components enter the evaporator 22 to minimize degradation ofthese components that become part of the reduced water-content material26. As one non-exhaustive example, the evaporator 22 may consist of oneor more vacuum cans (not shown) arranged either in series or inparallel, where a vacuum is created in the vacuum can(s) by a vacuumsource, such as a vacuum pump. One suitable example of the evaporator 22is a SENIOR™ vacuum chamber that is available from Kussel EquipmentCompany of Watertown, Wis. An ELMO®-P vacuum pump that may be obtainedfrom Siemens Aktiengesellschaft of Munich, Germany may be used as thevacuum source for the SENIOR™ vacuum chamber.

Water 24 may be sequentially removed by multiple passes through theevaporator 22 or may be removed in one pass through the evaporator 22 bypermitting a longer residence time of the mixed liquid feed material 20in the evaporator 22. The purpose of removing water 24 in the evaporator22 is to concentrate the interfacial butter solids of the butter that isused in or as the feed material 12. Therefore, the evaporator 22preferably removes water 24 from the mixed liquid feed material 20without removing any interfacial butter solids from the mixed liquidfeed material 20.

Any technique that is capable of removing water from the feed material12 or the mixed liquid feed material 20 maybe substituted in place ofthe evaporator 22, so long as the technique is capable of minimizing,and preferably eliminating, removal of interfacial butter solids fromthe feed material 12 or from the mixed liquid feed material 20. Forexample, as an alternative to the evaporator 22, the feed material 12 orthe mixed liquid feed material 20 may be subjected to freeze drying orspray drying to reduce the concentration of water in the feed material12 or in the mixed liquid feed material 20. However, the process 10preferably employs the evaporator 22 instead of freeze drying, sincewater removal using the evaporator 22 is less complicated than freezedrying and relies on equipment conventionally used in the dairy industryfor water removal. Also, the process 10 preferably employs theevaporator 22 instead of spray drying, since spray drying would beexcepted to cause undesirable oxidation of one or more components of themixed liquid feed material 20.

The separator 28 may be any piece of equipment (not shown), such asgravity separation equipment (a settling tank, for example) ormechanical separation equipment (a centrifuge, for example), thatpermits the aqueous phase and the butterfat phase of the butter toseparate into substantially distinct layers and thereby permitsseparation of the reduced water-content material 26 into the butterfat30, the byproduct butterfat 31, and the butter solids intermediate 32.The butterfat 30 and the byproduct butterfat 31 primarily containbutterfat. The butterfat and the byproduct butterfat 31 may also containa small amount of aqueous phase material of the type that forms themajority of the butter solids intermediate 32, though the amount ofaqueous phase material in the butterfat 30 and the byproduct butterfat31 is preferably minimized. The butter solids intermediate 32 primarilycontains water and water-soluble components along with the majority ofthe interfacial butter solids. The butter solids intermediate 32 mayalso contain a small amount of butterfat and butterfat-solublecomponents to maximize capture of interfacial butter solids, such asphospholipids, in the butter solids intermediate 32, though the amountof butterfat in the butter solids intermediate 32 is preferablyminimized to a degree that is consistent with maximizing recovery ofinterfacial butter solids, such as phospholipids, in the butter solidsintermediate 32.

Furthermore, multiple pieces of equipment may be provided thatcollectively operate as the separator 28. For example, the separator 28may include a pair of settling tanks (not shown) that are arranged inseries. In one of the tanks, the reduced water-content material 26 maybe separated into a butterfat component (not shown) and the buttersolids intermediate 32. Thereafter, the butterfat component may beseparated into the butterfat 30 and the byproduct butterfat 31. Ofcourse, alternative separation equipment, such as a centrifuge, may besubstituted in place of one or both of these tanks.

Preferably, stratification of the butterfat phase and the aqueous phaseof the butter occurs in the separator 28 to a substantial degree tomaximize separation of butterfat 30 and interfacial butter solids in theseparator 28. When the separator 28 is a gravity separator, such as asettling tank, it has been determined that operating temperatures aboveabout 145° F. (above about 62.8° C.) in the separator 28 tend to reduceseparation efficiency and consequently may cause undesirably highamounts of interfacial butter solids to be retained in the butterfatand/or the byproduct butterfat 31.

One example of a suitable piece of equipment that may serve as theseparator 28 or as a component of the separator 28 is the BMRPX-S314centrifuge that may be obtained from Alfa-Laval Separation, Inc. ofWarminster, Pa. The BMRPX-S314 centrifuge may have a bowl speed of about5,000 revolutions per minute (rpm), though the bowl is preferablypowered by a variable speed drive that permits adjustment of the bowlspeed to minimize, and preferably eliminate, loss of interfacial buttersolids due to the afore-mentioned U.S.D.A.-mandated “burping” of theseparator 28. For the BMRPX-S314 centrifuge, the top of the separatorbowl is preferably maintained at a temperature above the melting pointof butter, using a warm water bath, to prevent butterfat fromsolidifying and plugging the outlet for the aqueous phase (intermediatebutte solids 32). If any clumps of solidified butterfat begin to form inthe BMRPX-S314 centrifuge, these clumps may plug the outlet for theaqueous phase and cause loss of some of the aqueous phase (intermediatebutte solids 32), and thus loss of some of the interfacial buttersolids, to the butterfat 30 and/or the byproduct butterfat 31.

As a general guideline, the degree of interfacial butter solidsseparation into the butter solids intermediate 32 versus interfacialbutter solids separation into the butterfat 30 and/or the byproductbutterfat 31 may be gauged by the visual clarity of the butterfat 30and/or the byproduct butterfat 31. If the butterfat 30 and/or thebyproduct butterfat 31 are cloudy in appearance, it is likely that asignificant amount of the interfacial butter solids has wound up in thebutterfat 30 and/or the byproduct butterfat 31, as opposed to the buttersolids intermediate 32. On the other hand, if the butterfat 30 and/orthe byproduct butterfat 31 are each fairly clear (though colored) inappearance, most, if not all or predominantly all, of the interfacialbutter solids have been separated into the butter solids intermediate32, as opposed to the butterfat 30 and/or the byproduct butterfat 31.

The purpose of the separator 28 is to permit splitting of the reducedwater-content material 26 into the butterfat 30, the byproduct butterfat31, and the butter solids intermediate 32. Operation of the separator 28preferably maximizes the concentration of interfacial butter solids inthe butter solids intermediate 32 and minimizes the concentration ofinterfacial butter solids in the butterfat 30 and in the byproductbutterfat 31. More preferably, the butter solids intermediate 32 that isdischarged from the separator 28 contains at least about 95 weightpercent, or more, of the interfacial butter solids originally present inthe feed material 12, and the butterfat 30 and the byproduct butterfat31 that exit the separator 28 collectively contain little, if any, ofthe interfacial butter solids, such as about 5 weight percent, or less,of the interfacial butter solids originally present in the feed material12.

Still more preferably, the separator 28 causes the butter solidsintermediate 32 to contain at least about 99 weight percent, or more, ofthe interfacial butter solids originally present in the feed material 12and causes about 1 weight percent, or less, of the interfacial buttersolids originally present in the feed material 12 to be in the butterfat30 and in the byproduct butterfat 31, collectively, that exit theseparator 28. Most preferably, operation of the separator 28 causes allof the interfacial butter solids originally present in the feed material12 to be in the butter solids intermediate 32 and yields butterfat 30and byproduct butterfat 31 that contain no or only de minimis amounts ofinterfacial butter solids.

The interfacial butter solids are predominantly formed of proteins,sugars (predominantly lactose), and phospholipids. Consequently, unlessotherwise indicated, all comments and statements that are providedherein about interfacial butter solids are equally applicable toproteins, sugars, and phospholipids, collectively. Thus, as anothergauge of the degree of separation of the interfacial butter solids intothe butter solids intermediate 32, as opposed to the butterfat 30 and/orthe byproduct butterfat 31, one may rely on degree of separation ofproteins, sugars, and phospholipids into the butter solids intermediate32 versus the degree of separation of proteins, sugars, andphospholipids into the butterfat 30 and/or the byproduct butterfat 31.The amount and concentration of proteins and sugars in a particularsample, such as the butter solids intermediate 32, the butterfat 30, orthe byproduct butterfat 31, may be determined using the Solids Non-Fatdetermination procedure that is provided below in the PROPERTY ANALYSISAND CHARACTERIZATION PROCEDURE section of this document. Likewise, theamount and concentration of phospholipids in a particular sample, suchas the butter solids intermediate 32, the butterfat 30, or the byproductbutterfat 31, may be determined using the Phospholipids determinationprocedure that is provided below in the PROPERTY ANALYSIS ANDCHARACTERIZATION PROCEDURE section of this document. The resultsobtained from the Solids Non-Fat determination procedure and from thePhospholipids determination procedure may be combined to determine theamount and concentration of proteins, sugars, and phospholipids,collectively, in a particular sample, such as the butter solidsintermediate 32, the butterfat 30, or the byproduct butterfat 31.

Operation of the separator 28 preferably maximizes the concentration ofproteins, sugars, and phospholipids, collectively, in the butter solidsintermediate 32 and minimizes the concentration of proteins, sugars, andphospholipids, collectively, in the butterfat 30 and in the byproductbutterfat 31. More preferably, the butter solids intermediate 32 that isdischarged from the separator 28 contains at least about 95 weightpercent, or more, of the proteins, sugars, and phospholipids,collectively, that were originally present in the feed material 12, andthe butterfat 30 and the byproduct butterfat 31 that exit the separator28 collectively contain little, if any, of the proteins, sugars, andphospholipids, such as about 5 weight percent, or less, collectively ofthe proteins, sugars, and phospholipids originally present in the feedmaterial 12.

Still more preferably, the separator 28 causes the butter solidsintermediate 32 to contain at least about 99 weight percent, or more, ofthe proteins, sugars, and phospholipids, collectively, that wereoriginally present in the feed material 12 and causes about 1 weightpercent, or less, of the proteins, sugars, and phospholipids,collectively, that were originally present in the feed material 12 to bein the butterfat 30 and in the byproduct butterfat 31, collectively,that exit the separator 28. Most preferably, operation of the separator28 causes all of the proteins, sugars, and phospholipids originallypresent in the feed material 12 to be in the butter solids intermediate32 and yields butterfat 30 and byproduct butterfat 31 that contain no oronly de minimis amounts of proteins, sugars, and phospholipids.

The purpose of removing water 24 in the evaporator 22 and removing thebutterfat 30 and the byproduct butterfat 31 in the separator 28 is tomaximize the concentration of interfacial butler solids in the buttersolids intermediate 32. The butter solids intermediate 32 serves as abuilding block for creating products that have a higher concentration ofinterfacial butter solids than ordinarily present in butter. Some of thebutterfat 30, some optional non-dairy fat 44, and some optionalaqueous-phase material may be combined with the butter solidsintermediate 32 to attain products having an elevated concentration ofinterfacial butter solids, a desired butterfat content, a desirednon-dairy fat concentration, as well as, a desired fat profile.

Ultimately, a major goal of the interfacial butter solids in the buttersolids intermediate 32 via the process 10 is to permit preparation ofbutter-based products, such as butter and/or the butter/margarine blend,that have an enhanced concentration of interfacial butter solids, ascompared to the concentration of interfacial butter solids ordinarilypresent in butter. This enhancement of the interfacial butter solidscontent in butter and/or butter/margarine blends that may be producedaccording to the present invention causes the produced butter and/orbutter/margarine blends to have improved butter taste and butter-bakingcharacteristics, even as compared to the butter that forms all or partof the feed material 12.

To maximize the recovery of interfacial butter solids in the buttersolids intermediate 32, some water may be, and typically is, allowed toremain in the reduced water-content material 26 that leaves theevaporator 22, and some butterfat maybe allowed to remain in the buttersolids intermediate 32 that exits the separator 28. Permitting somewater to remain in the reduced water-content material 26 typically helpsto minimize, or even eliminate, losses of interfacial butter solids viathe water 24 that exits the evaporator 22 and via the butterfat 30 andthe byproduct butterfat 31 that exit the separator 28, respectively.Likewise, permitting a small amount of butterfat to remain in the buttersolids intermediate 32 may help to minimize, or even eliminate, lossesof interfacial butter solids via the butterfat 30 and the byproductbutterfat 31 that exit the separator 28, respectively.

Also, water 24 may optionally be removed without removing any butterfat30 and/or any byproduct butterfat 31, or butterfat 30 and/or byproductbutterfat 31 may be removed without removing any water 24, if desired,to attain particular properties in the butter solids intermediate 32 (asconcentrated butter), the intermediate blend 46, the liquid/margarineblend 52, and/or the solidified butter/margarine blend 56. However, theconcentration of water and the concentration of butterfat in the buttersolids intermediate 32 is preferably minimized, to the extent possible,consistent with the goal of preferably maximizing the amount ofinterfacial butter solids retained in the butter solids intermediate 32versus the amount of interfacial butter solids originally present in thefeed material 12. Furthermore, if butterfat 30 and/or byproductbutterfat 31 are removed without removing any water 24, addition of theoptional emulsifying agent(s) may be required to obtain the desiredwater-in-fat dispersion of the intermediate blend 46 and the liquidbutter/margarine blend 52.

Though the separator 28 is depicted as being located after theevaporator 22 in the process 10, some or all removal of the butterfat 30and/or the byproduct butterfat 31 may optionally occur prior to water 24removal. This scenario would offer the advantage of reducing the amountof fluid needing to be heated to evaporate the water 24 in theevaporator 22. However, it is presently believed that evaporation of thewater 24 prior to any butterfat 30 removal and any byproduct butterfat31 may cause some added flavor development as a result of short chainfatty acid cleavage from hydrolytic and/or hydrolysis reactionsoccurring during reflux contact between the butterfat and aqueouscomponents of the feed material 10 in the evaporator 22 It is thoughtthat the short chain fatty acids resulting from this cleavage may add tothe potent flavor profile realized in butter and butter/margarine blendsproduced according to the present invention. Therefore, based upon thispresent understanding, it is preferred that most, and more preferablyall, butterfat 30 removal and/or byproduct butterfat 31 removal occursafter water 24 removal.

After the reduced water-content material 26 has been split into thebutterfat 30, the byproduct butterfat 31, and the butter solidsintermediate 32, the butterfat 30 is placed into the holding tank 34,which primarily functions as an accumulation tank. The composition ofthe butterfat 30 is typically not modified in the holding tank 34 andnothing is typically combined with the butterfat 30 in the holding tank34. The holding tank 34 is preferably jacketed and equipped with atemperature controller to permit heating and/or cooling of the tank 34contents and consequent maintenance of the butterfat 30 in the tank 34as a liquid in a desired temperature range, such as at a temperature inthe range of about 105° F. (about 40.6° C.) to about 120° F. (about48.9° C.).

After the reduced water-content material 26 has been split into thebutterfat 30, the byproduct butterfat 31, and the butter solidsintermediate 32, the butter solids intermediate 32 is placed into theholding tank 36, which primarily functions as an accumulation tank. Theholding tank 36 is preferably jacketed and equipped with a temperaturecontroller to permit heating and/or cooling of the tank 36 contents andconsequent maintenance of any butterfat content of the butter solidsintermediate 32 in the tank 36 as a liquid at an appropriatetemperature, such as at a temperature in the range of about 105° F.(about 40.6° C.) to about 120° F. (about 48.9° C.).

The composition of the butter solids intermediate 32 is typically notmodified in the holding tank 36 and nothing is typically combined withthe butter solids intermediate 32 in the holding tank 36. Nonetheless,salt may optionally be added to, and dispersed within, the butter solidsintermediate 32 in the tank 36 to give the subsequently preparedintermediate blend 46 a desired salt content that is typically in therange of about 1.2 weight percent salt to about 1.8 weight percent salt,based on the total weight of the intermediate blend 46. The salt maybeany food-grade salt, such as sodium chloride. The optional salt ispreferably added as part of an aqueous salt slurry to assist inhomogeneously dispersing the salt within the butter solids intermediate32.

After separation of the water 24, the butterfat 30, and/or the byproductbutterfat 31 in the process 10, the butterfat 38, the butter solidsintermediate 40, and the optional non-dairy fat 44 may be selectivelymetered, in batch wise fashion, into the weigh and mix tank 42 at anyratio relative to each other. The relative amounts of butterfat 38,butter solids intermediate 40, and non-dairy fat 44 that are added tothe weigh and mix tank 42 maybe adjusted as desired to selectivelyattain desired properties in butter and butter-based products producedusing the process 10. Preferably, however, the relative amounts ofbutterfat 38, butter solids intermediate 40, and non-dairy fat 44 areselected to increase the concentration of interfacial butter solids inthe liquid butter/margarine blend 52, relative to the concentration ofinterfacial butter solids in the butter used as, or as part of the feedmaterial 12.

The butterfat 38, the butter solids intermediate 40, and the optionalnon-dairy fat 44 are preferably added to the tank 42 in a particularsequence to avoid the potential of forming a fat-in-water emulsionsince, absent proper sequencing, formation of a fat-in-water emulsionmay occur even at high liquid fat concentrations of 80 weight percent,or more, and low moisture concentrations of 20 weight percent, or evenless. To form the desired water-in-fat dispersion, rather than theundesired fat-in-water emulsion, the butterfat 38 and the optionalnon-dairy fat 44 are preferably added to the tank 42 and placed at anappropriate temperature, such as within the range of about 105° F.(about 40.6° C.) to about 120° F. (about 48.9° C.), to maintain thebutterfat 38 and any warm, optional non-dairy fat 44 as liquids. Theagitator (not shown) in the tank 42 is activated to homogeneously mixthe warm butterfat 38 and the optional non-dairy fat 44. With theagitator still activated, the butter solids intermediate 40 is thenpreferably added to the mixture of the butterfat 38 and the optionalnon-dairy fat 44, under high shear agitation, to form the intermediateblend 46. The butter solids intermediate 40 addition rate should be slowenough and the mixing conditions in the tank 42 should be aggressiveenough to cause formation of the intermediate blend 46 as thewater-in-fat dispersion, preferably with the preferred continuous liquidfat phase.

The temperatures of the butterfat 38, the optional non-dairy fat 44, andthe butter solids intermediate 40 may be selected to achieve a mixturetemperature in the tank 42 of about 105° F. (about 40.6° C.) to about120° F. (about 48.9° C.) unless precrystalization of some fat is desiredin the intermediate blend 46. Maintaining a lower temperature in eachtank 42 on the order of about 80° F. (about 26.7° C.) to about 92° F.(about 33.3° C.) will typically cause a small amount of crystallizablefat in the intermediate blend 46 to be precrystalized as solid fatcrystals in the continuous fat phase of the intermediate blend 46. Whensuch precrystalization is desired, the solid fat crystals preferablyform to a degree in the continuous fat phase of the intermediate blend46 that increases the viscosity of the continuous fat phase andconsequently permits the continuous fat phase to hinder, and morepreferably eliminate, coalescence of aqueous droplets. Theprecrystalized fat acts as nuclei that promote an increased rate ofcrystallization in the crystallization equipment, such as the sweptsurface heat exchanger 54. Alternatively, the intermediate blend 46containing pre-crystalized fat, after passing through the blend tank 50,may be placed in tote or barrel packages for subsequent quiescentcrystallization.

The butterfat 38, the optional non-dairy fat, and the butter solidsintermediate 40 that are added to the tank 42 are each heated totemperatures that, upon addition of the butter solids intermediate 42 toeither the butterfat 38 or the fat blend of the butterfat 38 and theoptional non-dairy fat 44, (1) will permit uniform dispersion of thebutter solids intermediate 40 in the butterfat 38 or in the fat blendand (2) will cause formation of the intermediate blend 46 as the stablewater-in-fat dispersion that is preferably based on the continuous fatphase. When precrystalization in the intermediate blend 46 is desired,the two objectives noted above along with the desired precrystalizationmay typically be achieved with the butterfat 38 or the fat blend at atemperature ranging from about 110° F. (about 43.3° C.) to about 125° F.(about 51.7° C.) and with the butter solids intermediate 40 at atemperature ranging from about 60° F. (about 15.6° C.) to about 80° F.(about 26.7° C.). Mixing the butterfat 38 or the fat blend and thebutter solids intermediate 40 that are within these temperature rangeswill typically yield the intermediate blend 46 at a temperature rangingfrom about 80° F. (about 26.7° C.) to about 92° F. (about 33.3° C.) attypical blend ratios of the butterfat 38 or the fat blend to the buttersolids intermediate 40. When precrystalization in the intermediate blend46 is not desired, the two objectives noted above along with the desiredlack of precrystalization may typically be achieved with the butterfat38 or the fat blend at a temperature ranging from about 120° F. (about48.9° C.) to about 140° F. (about 60° C.) and with the butter solidsintermediate 40 at a temperature ranging from about 100° F. (about 37.8°C.) to about 120° F. (about 48.9° C.). Mixing the butterfat 38 or thefat blend and the butter solids intermediate 40 that are within thesetemperature ranges will typically yield the intermediate blend 46 at atemperature ranging from about 105° F. (about 40.6° C.) to about 120° F.(about 48.9° C.) at typical blend ratios of the butterfat 38 or the fatblend to the butter solids intermediate 40.

Of course, the exact temperatures selected for the butter solidsintermediate 40, the butterfat 38 or the fat blend of the butterfat 38,and the optional non-dairy fat 44, respectively, to achieve (1) uniformdispersion of the butter solids intermediate 40 in the butterfat 38 orin the fat blend and (2) formation of the intermediate blend 46 as thestable water-in-fat dispersion depend upon at least the followingfactors: (1) the concentration of interfacial butter solids in thebutterfat 38 and in the butter solids intermediate 40, (2) the ratio ofthe butterfat 38, the butter solids intermediate 40, and the optionalnon-dairy fat 44 to each other in the intermediate blend 46, (3) thenature of the non-dairy fat 44, (4) the fat profile of butterfat 38 orof the blend of the butterfat 38 and any optional non-dairy fat 44, (5)mixing conditions (such as mixing severity and component temperatures)in the tank 42, and (6) the concentration of any optional emulsifyingagent in the butterfat 38 or in the fat blend.

The weigh and mix tank 42 is preferably jacketed to permit heating andcooling of the tank 42 to attain and maintain a desired temperature ofcomponents that are added to, and blended together in, the mix tank 42.The process 10 may include a plurality of the tanks 42 that are arrangedin parallel with each other. This permits filling and mixing to occur inone of the tanks 42 while the contents of another of the tanks 42 arebeing transferred to the blend tank 50 for further processing. In oneembodiment, each tank 42 has a capacity of about 600 gallons (about 2271liters) and includes a center post agitator with agitation enhancementbaffles that are attached within the tank. Any conventional agitationmechanism may be employed in each tank 42, so long as mixing that isadequate to insure creation of the desired water-in-fat dispersion mayoccur in each tank 42. Additionally, each tank 42 preferably has aslanted, cone-shaped bottom to permit complete emptying of the tank(s)42. One suitable example of the tank(s) 42 is the WPDA (600 gallon/2271liter capacity) process tank that is available from WaukeshaChery-Burrell of Delavan, Wis.

For the purpose of modifying the fat profile of the intermediate blend46, the optional non-dairy fat 44 may be substituted in the weigh andmix tank 42 for some of the butterfat 38 that would ordinarily be addedto attain a particular concentration of fat in the intermediate blend46. Thus, in addition to creating a product with an increasedconcentration of interfacial butter solids, as compared to theconcentration of interfacial butter solids ordinarily present in butter,the process 10 may also be utilized to change the fat profile in theproduct from the fat profile originally present in the butter of thefeed material 12. Some non-exhaustive examples of suitable non-dairyfats 44 include animal fats, such as lard and beef tallow; plant fats,such as shortening, vegetable oil, and tropical oils; marine oils, suchas kelp oil and seaweed oil; fish oil, such as menhaden oil; and any ofthese in any combination Some non-exhaustive examples of suitablevegetable oils include corn oil, peanut oil, soybean oil, canola oil,olive oil, and any of these in any combination. Some non-exhaustiveexamples of suitable tropical oils include coconut oil, palm oil, palmkernel oil, and any of these in any combination.

Any of the components of the non-dairy fat 44, if normally in the liquidphase at a particular temperature, may be hydrogenated to harden thenon-dairy fat 44 and thereby modify the viscosity and phase of thenon-dairy fat 44, as desired. Furthermore, the non-dairy fat 44 may beselected to achieve desired properties in the liquid butter/margarineblend 52 and in the solidified butter/margarine blend 56. For example,the non-dairy fat 44 may be selected to achieve, upon mixing with thebutter solids intermediate 40 and any added butterfat 38 and subsequentprocessing in the process 10, a particular amount of hardness orsoftness in the solidified butter/margarine blend 56 or to permit theliquid butter/margarine blend 52 to serve as the final product of theprocess 10. Thus, after concentrating the interfacial butter solids inthe butter solids intermediate 32, the non-dairy fat 44 may beselectively chosen and added to the tank 42 to achieve particularproperties in the liquid butter/margarine blend 52 and/or in thesolidified butter/margarine blend 56 that are desired by a particularcustomer or that are more suitable for a particular application of theliquid butter/margarine blend 52 or the solidified butter/margarineblend 56.

Though it is permissible to add non-dairy fat 44 to the butter solidsintermediate 40 and any butterfat 38 that is added to the tank 42, it islikewise also permissible to add butter solids intermediate 40 andbutterfat 38, without adding any non-dairy fat 44, to the tank 42. Thisalternative would produce the intermediate blend 46 with a concentratedlevel of interfacial butter solids, as compared to the concentration ofinterfacial butter solids in the butter of the feed material 12, whilemaintaining the original fat profile of the butter of the feed material12.

Though not depicted, it is permissible to add the non-dairy fat 44 priorto the weigh and mix tank 42. For example, some or all of the non-dairyfat 44 may be included as part of the feed material 12. Preferably,however, the non-dairy fat 44 is not included as part of the feedmaterial 12, since this would increase the volume of the feed material12 needing to be heated to effect evaporation of the water 24. Also, thenon-dairy fat 44 may be added prior to removal of the butterfat 30.However, the non-dairy fat 44 is preferably not added prior to removalof the butterfat 30, since this would increase the size needed for theseparator 28 and would make it challenging, if not impossible, to removebyproduct butterfat 31 in the separator 28 without removing anynon-dairy fat 44. Removal of a combined fat stream containing bothbyproduct butterfat 31 and non-dairy fat 44 would typically be expectedto diminish the market value of any byproduct butterfat 31. Similarconsiderations would apply if byproduct butterfat were removed from thebutterfat 30 after separation of the butterfat 30 and the butter solidsintermediate 32 in the separator 28.

The weigh and mix tank 42 is ordinarily only used for blending thebutterfat 38, the butter solids intermediate 40, and the optionalnon-dairy fat 44. However, it is permissible to add aqueous ingredientsand ingredients in aqueous solution at the weigh and mix tank 42,preferably after addition of the butter solids intermediate 40, so thatthese aqueous ingredients and aqueous solutions of ingredients areincorporated as part of the water-in-fat dispersion that exits the weighand mix tank 42 as the intermediate blend 46. One example of a suitableaqueous ingredient is water. Some non-exhaustive examples of aqueoussolutions of ingredients include sweeteners, such as molasses and maltsyrup. Furthermore, small amounts of liquid dairy materials, such asmilk, cream, whey, whey protein concentrate, and any combination of anyof these, may be added to the weigh and mix tank 42 for incorporationinto the water-in-fat dispersion for any desired purpose, such asmodifying the viscosity of the water-in-fat dispersion that exits thetank 42 as the intermediate blend 46.

After exiting the weigh and mix tank 42, the intermediate blend 46 iscombined with the additive(s) 48 in the blend tank 50. Somenon-exhaustive examples of the additive(s) 48 include coloring agent(s);vitamins and minerals, such as Vitamin A and betacarotene; otherconventional additives to margarines and fat-based spreads; and any ofthese in any combination. The additive(s) 48 may include any individualcomponent or any combination of any of the components at anyconcentration. The combination of the intermediate blend 46 and theadditive(s) 48 is subjected to mild agitation in the blend tank 50 toblend the additive(s) 48 into the water-in-fat dispersion (intermediateblend 46) previously formed in the tanks(s) 42.

The blend tank 50 is preferably jacketed and equipped with a temperaturecontroller to permit heating and cooling of the tank 50 and consequentmaintenance of the components that are added to, and blended togetherin, the blend tank 50 at a desired temperature. In the process 10,though only one of the tanks 50 is typically required, two or more ofthe tanks 50 may be employed if multiple tanks 42 arc used, sincefilling of the tank 50, processing of the components in the tank 50, andemptying of the tank 50 ordinarily takes more time than each cycle offilling the tank 42 and forming the water-in-fat dispersion in the tank42 that is preparing the next batch for the tank 50. In one embodiment,the tank 50 has the same configuration as the tank 42 and has a capacityof about 600 gallons (about 2271 liters. Therefore, one suitable exampleof the tank 50 is the WPDA (600 gallon/2271 liter capacity) process tankthat is available from Waukesha Cherry-Burrell of Delavan, Wis.

After being formed in the tank 50, the liquid butter/margarine blend 52may be transferred to the crystallizing equipment, such as the sweptsurface heat exchanger 54. In the swept surface heat exchanger 54, theliquid butter/margarine blend 52, under heavy mechanical treatment andrapid cooling, is super cooled and crystalized to transform thewater-in-fat dispersion created in the tank 42 and maintained in thetank 50 into a water-in-fat matrix and to stabilize and work thewater-in-fat matrix. One suitable example of the swept surface heatexchanger 54 is the Votator® 672DE swept surface heat exchanger that isavailable from Waukesha Cherry-Burrell of Delavan, Wis. Though the sweptsurface heat exchanger 54 is depicted in the process 10, any equipment,such as a chilled miler type of exchanger, that is capable ofsupercooling the water-in-fat dispersion from the tank 50 and causingcrystallization of fat in the water-in-fat dispersion to form thewater-in-fat matrix may be substituted in place of the swept surfaceheat exchanger 54.

As yet another alternative, the liquid butter/margarine blend 52 may besent directly to the packing equipment 58, without undergoing thecooling and crystallization in the swept surface heat exchanger 54, inthose applications where it is desired for the final packaged product tobe in a liquid form. As another example, where the tank 42 has beenoperated at a lower temperature to attain some precrystalization of fatin the intermediate blend 46, and where this precrystalization has beenmaintained or enhanced in the tank 50, fat in the liquidbutter/margarine blend 52 may be permitted to complete the desiredamount of crystallization after being placed in packaging in the packingequipment 58.

The method of the present invention, such as the method utilized inconjunction with the process 10, permits conversion of the feed material12 that is butter with a certain weight percent Y of interfacial buttersolids, based upon the total weight of the butter, into concentratedbutter having an interfacial butter solids concentration that has beenincreased, relative to the concentration of interfacial butter solidsoriginally present in the butter, to any multiple, such as 1.1, 2.0,2.5, 3.0, 3.5, 4.0, etc., of the Y concentration of interfacial buttersolids in the butter of the feed material 12. This is accomplished byremoving sufficient water 24 and/or butterfat 30 from the feed 12followed by addition of a select amount of butterfat 38 and/or non-dairyfat 44 to a select amount of the butter solids intermediate 40 in theweigh and mix tank 42.

Likewise, where the feed material 12 includes one or more components inaddition to butter, the method of the present invention, such as themethod utilized in conjunction with the process 10, permits conversionof the feed material 12 containing a certain weight percent Z ofinterfacial butter solids, based upon the total weight of the feed 12,into a butter/margarine blend having an interfacial butter solidsconcentration that has been increased, relative to the concentration ofinterfacial butter solids in the feed material 12, to any multiple, suchas 1.1, 2.0, 2.5, 3.0, 3.5, 4.0, etc., of the Z concentration ofinterfacial butter solids in the feed material 12. This is similarlyaccomplished by removing sufficient water 24 and/or butterfat 30 fromthe feed material 12 followed by addition of a select amount ofbutterfat 38 and/or non-dairy fat 44 to a select amount of the buttersolids intermediate 40 in the weigh and mix tank 42.

The water 24, the butterfat 30, and the byproduct butterfat 31 may beremoved in any ratio, relative to each other, to achieve a desiredconcentration of the interfacial butter solids in the butter solidsintermediate 40. Thereafter, the butter solids intermediate 40 and thebutterfat 38 may be blended together in the tank 42 in any ratio that iseffective to achieve a desired concentration of the interfacial buttersolids in the butter solids intermediate 40 that is preferably greaterthan the concentration of interfacial butter solids in the feed material12. Furthermore, if desired, non-dairy fat 44, such as any of theafore-mentioned non-dairy fats, maybe added with the butterfat 38 orsubstituted in place of some of the butterfat 38 to modify the fatprofile of the intermediate blend 46, as compared to the fat profile ofthe feed material 12.

The net result is that butter-based products, such as concentratedbutter and butter/margarine blends, that contain a higher concentrationof interfacial butter solids than in the feed material 12 may beproduced using the process 10. This is important, because it has beenfound that the phospholipids portion of the interfacial butter solidsenhances the body of baked goods during the baking process and gives therich characteristic “butter” flavor and mouthfeel to productsincorporating the intermediate blend 46 or products derived from theintermediate blend 46, without using any artificial flavoring tosimulate the “butter” taste. Indeed, the ability to concentrate theinterfacial butter solids in products produced in accordance with thepresent invention enhances the body yielding capabilities, beyond theenhancement provided by butter alone, during baking and enhances thebutter taste and characteristic mouth-feel beyond that contributed bybutter alone, prior to processing of the butter in accordance with thepresent invention.

Furthermore, the protein and lactose components of the interfacialbutter solids enhance the browning properties of products that includethe interfacial butter solids. Therefore, increasing the interfacialbutter solids concentration in the intermediate blend 46 and derivativesof the intermediate blend 46, as compared to the concentration ofinterfacial butter solids present in butter prior to processing inaccordance with the present invention, enhances the browning propertiesof goods incorporating butter-based products, such as concentratedbutter s and butter/margarine blends, that are prepared in accordancewith the present invention. Additionally, the ability to modify the fatprofile and to likewise control the softness/hardness of butter-basedproducts of the present invention, such as butter/margarine blends, byincorporating the non-dairy fat 44 in place of some of the butterfatoriginally present in the feed material 12, while concentrating theinterfacial butter solids content compared to the original feed material12, generates innumerable flexible use opportunities for butter-basedproducts, such as concentrated butter s and butter/margarine blends,that are prepared in accordance with the present invention, whileretaining the enhanced butter flavor, baking, and browning properties ofthe butter/margarine blends of the present invention.

Finally, the ability to create butter-based products, such asconcentrated butter s and butter/margarine blends, that excludepreservatives and include only natural ingredients, such as butter,salt, natural coloring agents, and natural, non-dairy fat, such asvegetable oil, permits marketers of butter-based products produced inaccordance with the present invention to market these butter-basedproducts as natural products having only natural ingredients on theingredient list. When marketing these improved butter-base products,such as concentrated butter s and butter/margarine blends, there isoften no need to include long chemical names for artificial ingredients,emulsifying agents, such as monoglycerides and diglycerides, andpreservatives, such as potassium sorbate and sodium benzoate, since theconcentrated butter s and butter/margarine blends of the presentinvention may often be, and preferably are, produced without addingartificial ingredients, such as monoglycerides, diglycerides, potassiumsorbate and sodium benzoate.

Property Analysis and Characterization Procedure

Unless otherwise indicated, all determinations of moistureconcentration, fat concentration, salt concentration, and solids non-fatconcentration are made in accordance with the following procedure. Thisprocedure involves the sequential determination of moistureconcentration, then the fat concentration, then the salt concentration,and finally the solids non-fat concentration on a particular sample.Specifically, a weighed sample is first heated to evaporate moisture andthen is re-weighed to measure the moisture lost. Then, fat is extractedfrom the sample using petroleum ether, and the solids remaining in thesample are then re-weighed to determine the fat concentration. Next, theremaining sample is dissolved in hot water and the salt concentration isdetermined by titration. Finally, the moisture concentration, the fatconcentration, and the salt concentration that have been determined forthe sample are subtracted from 100% to determine the solids non-fatconcentration of the sample. These procedures for moistureconcentration, fat concentration, salt concentration, and solids non-fatconcentration determination are detailed more fully below.

All samples are refrigerated at 4° C., unless being prepared for sampleanalysis. Samples that are being prepared for analysis must fist betempered to room temperature (about 20° C. to about 25° C.) prior tosample analysis.

Moisture Determination

To determine the moisture concentration of an original sample, a clean,dry aluminum beaker that has been tempered to room temperature (about20° C. to about 25° C.) is weighed on an analytical balance with asensitivity of 0.1 milligrams. The material to be sampled is then warmedand mixed to permit a representative sample to be taken. This warming ofthe material to be sampled may be done by heating the material to besampled in a water bath at a temperature between about 32° C. and about35° C. Care must be taken to avoid any phase separation in the sample.Phase separation of liquid butter will typically not occur initially andwill be delayed for a period of time if the temperature of the waterbath is held below about 43° C. Alternatively, the material to besampled may be warmed at room temperature until the material reaches aconsistency that permits mixing and subsequent sampling of the material.

About 10 grams of a well mixed sample (the “original sample”) is placedinto the aluminum beaker and accurately weighed on the analyticalbalance. The sample in the aluminum beaker is then heated on a hot plateor an equivalent heat source, while swirling the sample continuously toavoid spattering and burning of any milk solids contained in the sample.Heating is continued to cause evaporation of water from the sample untilall foaming and bubbling of the sample has stopped and any milk solidscontained in the sample appear light brown in color.

For oil and butterfat samples that contain little moisture, evaporationof any moisture content may only take between about 30 and about 60seconds. Care should be taken to obtain a uniform color between eachsample being analyzed for water concentration. If a dark brown colorappears in the sample that is being heated, the milk solids content ofthe sample have been burned and this sample should be rerun.

After evaporation on the hot plate has been completed, the aluminumbeaker is cooled to room temperature (about 20° C. to about 25° C.).Thereafter, the aluminum beaker and its contents are weighed on theanalytical balance and the weight is recorded as the “weight ofbeaker+moisture-free residue.

The weight percent of moisture in the sample, based on the total weightof the sample, may be determined in accordance with the followingcalculations:${{Weight}\quad {of}\quad {Original}\quad {Sample}} = {{{\left\lbrack {\left( {{{Weight}\quad {of}\quad {beaker}} + {{original}\quad {sample}}} \right) - {{weight}\quad {of}\quad {beaker}}} \right\rbrack \% \quad {Moisture}} = {\frac{\begin{matrix}{\left( {{{Weight}\quad {of}\quad {beaker}} + {{original}\quad {sample}}} \right) -} \\\left( {{{Weight}\quad {of}\quad {beaker}} + {{moisture}\text{-}{free}\quad {residue}}} \right)\end{matrix}}{{Weight}\quad {of}\quad {Original}\quad {Sample}} \times 100}}}$

Fat Analysis

The fat concentration of the original sample is then determined byplacing the aluminum beaker containing the moisture-free residue fromthe moisture-determination step in a slanted beaker holder under anexhaust hood. Then, 100 milliliters of petroleum ether is measured intothe aluminum beaker. Next, the mixture of the sample and the added etheris stirred using a rubber policeman to dissolve the fat contained in thesample. Stirring is then stopped and the sample is allowed to rest forat least about 3 minutes to permit any solids in the sample to settle.Thereafter, using a vacuum source, the ether/fat mixture is carefullysuctioned from the beaker, while being careful not to suction any of themilk solids that have dropped to the bottom of the beaker.

Then, 75 milliliters of petroleum ether is measured into the beaker andthe contents of the beaker are again stirred with the rubber policemanto dissolve additional fat. Stirring is again stopped and the beaker isallowed to rest at least 3 minutes to permit solids to settle to thebottom of the beaker. The vacuum source is again applied to suction themixture of ether and fat from the beaker, while being careful not tosuction any milk solids from the beaker.

Fifty milliliters of petroleum ether is placed into the beaker andstirred again with the rubber policeman to dissolve any fat remaining inthe sample. The beaker is allowed to rest at least three minutes topermit settling of any solids in the beaker. The vacuum apparatus isagain applied to carefully suction the mixture of fat and ether from thebeaker, while again being careful not to suction any milk solids fromthe beaker.

The beaker is allowed to dry under the fume exhaust hood until thebeaker and its contents attain a constant weight, as determined bymeasurement on the analytical balance. After the beaker has attained aconstant weight, the weight of the beaker and its contents is determinedand this weight is recorded as “weight of beaker+fat-free residue”.Then, the weight percent of fat in the original sample, based upon thetotal weight of the original sample, is calculated using the followingformula: ${{\% \quad {Fat}} = {\frac{\begin{matrix}{\left( {{{Weight}\quad {of}\quad {beaker}} + {{Moisture}\text{-}{free}\quad {residue}}} \right) -} \\\left( {{{Weight}\quad {of}\quad {beaker}} + {{f{at}}\text{-}{free}\quad {residue}}} \right)\end{matrix}}{{Weight}\quad {of}\quad {Original}\quad {Sample}} \times 100}}$

Salt Analysis

Reverse osmosis/distilled water is heated to a temperature of about 65°C. to about 70° C. One hundred fifty (150) milliliters of the heatedwater is measured into the beaker containing the fat-free residueobtained in the fat analysis procedure. A rubber policeman is used tostir the contents of the beaker to dissolve the salt in the hot water.The beaker and its contents are allowed to cool to room temperature(about 20° C. to about 25° C.). A twenty-five milliliter sample of thewater/salt mixture in the beaker is withdrawn and pipetted into a 125milliliter Erlenmeyer flash To prevent withdrawal of milk solids fromthe beaker, the tip of the pipet must be held off of the bottom of thebeaker while withdrawing the water/salt sample. Two to three drops ofpotassium chromate indicator are placed in to the Erlenmeyer flask. Thecontents of the Erlenmeyer flask are then titrated with 0.0171 N(normal)silver nitrate solution until the first reddish-brown color lasting 30seconds is obtained in the sample being titrated. Thereafter, the weightpercent of salt, based upon the total weight of the original sample, isdetermined using the following formula:${\% \quad {Salt}} = {\frac{{milliliters}\quad {of}\quad {silver}\quad {nitrate}\quad \left( {AgNO}_{3} \right)}{{Weight}\quad {of}\quad {Original}\quad {Sample}} \times 100}$

Solids Non-fat Determination

After the weight percent of moisture, fat, and salt in the originalsample have been determined, these percentages are plugged into thefollowing formula to determine the weight percent of solids non-fat,based on the total weight of the original sample, that is contained inthe original sample:

% Solids non-fat=100%−(% Moisture+% Fat+% Salt)

General Comments About the Fat, Moisture, Salt, and Solids Non-fatDeterminations

The detection limit of this method for moisture, fat, salt, and solidsnon-fat is 0.01 weight percent. Any results less than 0.01 weightpercent should be reported as “less than 0.01 weigh percent”. At leastone duplicate analysis that includes moisture, fat, salt, and solidsnon-fat should be conducted each day the analysis is performed. Also, atleast one in every twenty samples should be analyzed in duplicate formoisture, fat, salt, and solids non-fat. Suitable differences betweenduplicates are listed below:

Moisture: 0.30 weight percent

Fat: 0.40 weight percent

Salt: 0.10 weight percent

Solids non-fat: 0.10 weight percent

Phospholipids Determination

Unless otherwise indicated, all determinations of phospholipidsconcentration are determined in accordance with the rapid highperformance liquid chromatography (rapid HPLC method) that is set forthin the article entitled Phospholipids in Milk and Dairy Products by W.W. Christie, R. C. Noble, and G. Davies that appears in Volume 40,Number 1 of the Journal of the Science of Dairy Technology datedFebruary, 1987. This Phospholipids in Milk and Dairy Products article isconsequently incorporated by reference in its entirety. All samples tobe analyzed in accordance with this Phospholipids Determinationprocedure are refrigerated at 4° C., unless being prepared for sampleanalysis. Samples that are being prepared for analysis in accordancewith this Phospholipids Determination procedure should first be temperedto room temperature (about 20° C. to about 25° C.) prior to sampleanalysis.

EXAMPLES

The present invention is more particularly described in the followingExamples which are intended as illustrations only since numerousmodifications and variations within the scope of the present inventionwill be apparent to those skilled in the art.

Example 1

This example illustrates use of the process of the present invention totransform a blend of salted butter and unsalted butter into abutter/margarine blend. First, a butter mixture with a weight of about3596 grams that contained about 59 weight percent salted butter andabout 41 weight percent unsalted butter, based on the total weight ofthe butter mixture, was placed in a heavy-bottom, stainless steel pan.The stainless steel pan was slowly heated to melt the blend of saltedbutter and unsalted butter. The moisture concentration of the meltedbutter blend was determined to be about 17.2 weight percent, based onthe total weight of the melted butter blend.

After determining the moisture concentration of the melted butter blend,the stainless steel pan was further heated on low to bring the meltedbutter blend to a rolling boil. The boiling butter blend was agitatedwith a Type RZRI lab mixer that may be obtained from Caframo, Ltd. ofWiarton, Ontario, Canada. The Cafrarno lab mixer was operated at setpoint 5. The Caframo lab mixer had a four blade mixer with an overallmixer blade diameter of 1⅞ inches (4.76 centimeters). The four blademixer was operated at about 1520 revolutions per minute (rpm). Whilebeing agitated, the temperature of the boiling butter blend ranged fromabout 208° F. (about 97.8° C.) to about 218° F. (about 103.3° C.). Thebutter blend was agitated and boiled to remove water until theconcentration of water in the boiling butter blend reached about 8.7weight percent, based on the total weight of the boiling butter blend.Thus, about 326 grams of the original 601 grams of water in the initialbutter blend were removed, leaving about 276 grams of water in theconcentrated butter blend that resulted from boiling the initial butterblend.

The concentrated butter blend obtained by evaporating water was thencooled and frozen overnight to help separate the aqueous phase of thebutter blend from the fat phase of the butter blend. The following day,the frozen concentrated butter blend was slowly reheated in thestainless steel pan to liquify the fat until the fat layer and aqueouslayer fully stratified. Then, 2783 grams of butterfat were extractedfrom the stratified concentrated butter blend to form a butter solidsintermediate that contained primarily water, interfacial butter solids,butterfat, and salt Thereafter, 755 grams of Cargill CV-65 canola oilavailable from Cargill Corporation of Minnetonka, Minn. and 761 grams ofthe withdrawn butterfat were combined and mixed to form a homogeneousfat mixture. Next, under conditions of high shear mixing, the buttersolids intermediate was slowly added to the homogeneous fat mixture ofthe butterfat and canola oil to form a water-in-fat dispersion with acontinuous fat phase.

After addition of the butter solids intermediate to the canola oil andthe butterfat, the water-in-fat dispersion was agitated while beingcooled to permit formation of the water-in-fat matrix characteristic ofmargarines and butter and to permit crystallization of the fat in thecompleted butter/margarine blend. Specifically, the mixture of thebutter solids intermediate, the canola oil, and the butterfat was placedinto a stainless steel beaker. The stainless steel beaker was thenplaced in an ice water bath. The Caframo type RZRI lab mixer was thenpositioned proximate the beaker with the mixer blade located in thebeaker. The mixer was then turned on at set point 5 at approximately1520 rpm to convert the mixture into a water-in-fat dispersion andcrystallize the butterfat. The beaker was rotated in a direction counterto the direction of the mixer blade rotation and a stainless steelspatula was used to continuously sweep solidified fat from the insidesurface of the beaker. This process was maintained until sufficient fathad solidified to form a fairly homogeneous mass.

The starting composition of the salted/unsalted butter blend and thefinal composition of the completed butter/margarine blend, along withcomponent removal and additional details, are presented in Table 1,which appears later in this example. Again, during the initialevaporation phase, 326 grams of water were removed from the aqueousphase of the melted butter blend. Thereafter, 2783 grams of butterfatwere removed and 755 grams of canola oil and 761 grams of the withdrawnbutterfat were added back to the in-process blend. Though no data wasobtained on the amount of interfacial butter solids initially present inthe salted/unsalted butter blend or in the completed butter/margarineblend, it is believed that all, or essentially all, of the interfacialbutter solids originally present in the salted/unsalted butter blendremained in the butter/margarine blend, since no solids were removedduring evaporation of the water and since no solids were visuallyobserved to have been removed during extraction of the butterfat fromthe salted/unsalted butter blend.

TABLE 1 Butter Components Added Feed Components To Butter ProductComposition Removal Solids Intermediate Composition Ingredient ComponentWt % Grams (grams) Ingredient Grams Component Wt % Grams Butter Water17.20 601.3 325.5 Water 14.48 275.7 Butterfat 80.29 2807 2783 Butterfat761 Butterfat 41.25 785 Salt 0.83 28.9 Salt 1.52 28.9 SNF* 1.68 58.6SNF* 3.08 58.6 Canola Oil 755 Canola Oil 39.67 755 TOTAL 100.00 3495.8TOTAL 1516 TOTAL 100.00 1903.2 *Solids Non-Fat

Samples of butter and samples of the butter/margarine blend produced inaccordance with this example were taste tested by a panel of tasters.The panel of tasters overwhelmingly preferred the taste of thebutter/margarine blend to the taste of the butter because thebutter/margarine blend had a richer butter taste than did the butteritself This is believed due to the higher interfacial butter solidsconcentration in the butter/margarine blend, versus the interfacialbutter solids concentration in the butter considered by the taste panel.The taste panel's preference of the butter/margarine blend over butteralone occurred even though the butter/margarine blend of this example,and thus the interfacial butter solids, were somewhat process abusedduring processing to form the butter/margarine blend, since the butterwas actually boiled to effect evaporation of water. Processing atreduced temperature conditions would be expected to further enhance thepreference of the taste panel for the butter/margarine blend.

Example 2

This example illustrates removal of butterfat and moisture from unsaltedbutter along with subsequent addition of vegetable oil and salt to forma butter/margarine blend. First, 3500 pounds (about 1588 kilograms) ofunsalted butter were melted in a steam jacketed melt tank at atemperature ranging from about 120° F. (about 48.9° C.) to about 140° F.(about 60° C.). The unsalted butter had the composition listed in Table2 below. The melted, unsalted butter was then passed through a vacuumcan that was maintained at about 28 inches (about 71 centimeters) ofmercury vacuum. The melted unsalted butter was introduced into thevacuum can at a temperature of about 200° F. (about 93.3° C.). Thevacuum can had a capacity of about 100 to about 150 gallons (about 378to about 568 liters) and was a SENIOR™ vacuum chamber that may beobtained from Kussell Equipment Co. of Watertown, Wis. Only about 20% ofthe volume of the vacuum can was occupied by the melted unsalted butterat any one time. About 276 pounds (about 125 kilograms) of water wereremoved from the melted unsalted butter in the vacuum can.

The reduced-water content unsalted butter produced in the vacuum can wasthen sent to a separator and permitted to separate into butterfat andbutter solids intermediate. In this example, the separator was theBMRPX-S314 separator that is available from Alfa-Laval Separation, Inc.This centrifuge had a bowl speed of about 5,000 revolutions per minute(rpm). Steam was injected into the reduced-water content unsalted butterprior to the separator to maintain a minimum temperature of about 150°F. (about 65.6° C.) at the inlet to the separator. This steam injectionwas determined to have added about 27 pounds (about 12.2 kilograms) ofwater to the reduced-water content unsalted butter prior to theseparator.

In the separator, the reduced-water content unsalted butter (includingthe added 27 pounds (about 12.2 kilograms) of steam injection water) wassplit into about 2,832 pounds (about 1285 kilograms) of butterfat andabout 419 pounds (about 190 kilograms) of butter solids intermediate.The butterfat and butter solids intermediate were each routed toseparate storage tanks. Thereafter, 800 pounds (about 363 kilograms) ofHM 1019 oil blend and 800 pounds (about 363 kilograms) of the withdrawnbutterfat were combined in a mix tank and were mixed to form ahomogeneous fat mixture. HM-1019 oil blend is a blend of partiallyhydrogenated soybean oil and partially hydrogenated cotton seed oil thatis available from Harvest States Coop of Mankota, Minn. Next, underconditions of high shear mixing in the mix tank about 352 pounds (about160 kilograms) of the butter solids intermediate (about 306 pounds(about 138 kilograms) of water (and phospholipids) and about 46 pounds(about 20.8 kilograms) of solids non-fat) was slowly added to thehomogeneous fat mixture of the butterfat and the HM 1019 oil blend toform a homogeneous water-in-fat dispersion with a continuous fat phase.Then, about 35.8 pounds (about 16.2 kilograms) of salt were combinedwith the water-in-fat dispersion in the mix tank. In this example, thehigh shear mixing was accomplished using a center post agitator and sidemounted baffles that were mounted within the mix tank.

Additionally, about 2.7 grams of betacarotene and about 29 grams ofVitamin A were added to the mix tank. The contents of the mix tank weremaintained at a temperature of about 115° F. (about 46.1° C.) andblended in the mix tank using the agitator to attain the homogeneouswater-in-fat dispersion. This dispersion was transferred from the mixlank to a blend tank where the dispersion was maintained using anagitator and baffle like those in the mix tank. Additionally, thedispersion was maintained at a temperature of about 115° F. (about 46.1°C.) in the blend tank.

The dispersion was pumped from the blend tank through a two-barrel sweptsurface heat exchanger, a Votator® 672DE swept surface heat exchangerthat is available from Waukesha Cherry-Burrell, to more fully developthe water-in-fat dispersion, crystalize fat, and thereby form abutter/margarine blend in accordance with the present invention. Theswept surface heat exchanger had both a lower barrel and an upperbarrel. The lower barrel predominantly accomplished crystallization offat in the water-in-fat dispersion, and the upper barrel thereafterworked the product of the lower barrel. The exit temperature of thelower barrel was about 80° F. (about 26.7° C.) and the exit temperatureof the upper barrel, after working, was set at about 60° F. (about 15.6°C.). The lower barrel was operated at about 550 to about 600 revolutionsper minute, whereas the upper barrel was found to cause minimal lumpingand produce a smooth product at an operating speed of about 510revolutions per minute.

The composition of the butter used as feed in this example and thecomposition of the butter/margarine blend product produced in thisexample, along with details about component removal from the butter feedand component addition to the butter solids intermediate arc present inTable 2 below:

TABLE 2 Pounds of Components Added Feed Butter To Butter ProductComposition Component Solids Intermediate Composition Pounds RemovalPounds Pounds Ingredient Component Wt % (kg) (kg) Ingredient (kg)Component Wt % (kg) Butter Water 17.75 612.5 276 Water 15.40 306.25(˜278) (˜125) (˜) Butterfat 82.10 2832 2832 Butterfat 800 Butterfat40.24 800 (˜1285) (˜1284) (˜363) (˜363) Salt 0.00 0 Salt 35.8 Salt 1.8135.8 (0) (˜16) (˜16) SNF* 0.15 55.1 SNF* 2.31 46 (˜25) (˜21) Oil** 800Oil** 40.24 800 (˜363) (˜363) TOTAL 100.00 3499.6 TOTAL 1636 TOTAL100.00 1988.05 (˜1588) (˜742) (˜902) *Solids Non-Fat **HM 1019 oil blend

In addition to the details provided in Table 2, it was determined thatthe interfacial butter solids produced at the separator weighed about419 pounds (about 190 kilograms) and included about 55.5 pounds (about25.2 kilograms) of solids non-fat and about 336.5 pounds (about 152.6kilograms) of water (and phospholipids). Of this 419 pounds (about 190kilograms) of butter solids intermediate, only about 352 pounds (about46 pounds (about 20.8 kilograms) of solids non-fat and about 306 pounds(about 139 kilograms) of water (and phospholipids)) were added to themix tank. The remaining 67 pounds (about 30.3 kilograms) of buttersolids intermediate produced at the separator and about 2,030 pounds(about 921 kilograms) of butterfat produced at the separator werediscarded and not used in forming the butter/margarine blend product ofthis example.

Example 3

This example illustrates removal of butterfat and moisture from lightlysalted butter along with subsequent addition of vegetable oil to form abutter/margarine blend. First, 2200 pounds (about 998 kilograms) ofsalted butter were melted in a steam jacketed melt tank at a temperatureranging from about 120° F. (about 48.9° C.) to about 140° F. (about 60°C.). The lightly salted butter had the composition listed in Table 3below. The melted butter was then processed through the third effect ofa triple effect evaporator that was maintained at about 25 inches (about63.5 centimeters) of mercury vacuum. The melted butter was introducedinto the evaporator at a temperature of about 136° F. (about 57.8° C.).

This third effect of the triple effect evaporator was actually afinishing effect for small volumes that followed a larger double effectevaporator. The double effect evaporator was not used in this example.Only the finishing effect (the third effect) was used for waterevaporation from the melted butter in this example. This finishingeffect evaporator was a falling film evaporator that is available fromMarriott Walker Corporation of Birmingham, Michigan. Vacuum on thisfalling film evaporator was provided by a thermal compressor that isavailable from Croll-Reynolds Company of Westfield, N.J. The evaporatorremoved approximately 292 pounds (about 132.5 kilograms) to about 300pounds (about 136 kilograms) of water from the melted butter.

The reduced-water melted butter was then sent to a separator to permitsplitting of butterfat and a butter solids intermediate. The buttersolids intermediate contained most of the interfacial butter solids fromthe reduced-water melted butter. The separator in this example was a 500gallon (1892 liter)jacketed steel tank equipped with a cone-shapedbottom. Thus, gravity separation was used to split the butterfat and thebutter solids intermediate in this example. Approximately 1,200 pounds(about 544 kilograms) to 1,250 pounds (about 567 kilograms) of butterfatwas removed from the separator tank. The butter solids intermediate thatwas removed from the separator was routed to a storage tank.

After the partial butterfat removal, the remaining contents (asbutterfat) of the separator tank were sent to a mix tank. This mix tankhad a cone-shaped bottom and a capacity of about 500 gallons (about 1892liters). The mix tank also had a center-mounted agitator andtank-mounted baffles. In the mix tank, 244 pounds (about 110.7kilograms) of HM508 oil blend and 131 pounds (about 59.4 kilograms) ofliquid soybean oil were combined with the butterfat contents transferredfrom the separator tank to form a homogeneous fat blend. The HM508 oilblend is a partially hydrogenated soybean oil that is available fromHarvest States Coop of Mankato, Minn. Thereafter, under conditions ofhigh shear mixing in the mix tank, the butter solids intermediate thatwas removed from the reduced-water melted butter in the separator wasslowly added to the homogeneous fat blend of the butterfat and the HM508oil blend to form a homogeneous water-in-fat dispersion with acontinuous fat phase. In this example, the high shear mixing wasaccomplished using the center post agitator and side mounted bafflesthat were mounted within the mix tank.

The water-in-fat dispersion was transferred from the mix tank to a sweptsurface heat exchanger. In this example, the swept surface heatexchanger was a two-barrel Votator® 672DE swept surface heat exchangerthat is available from Waukesha Cherry-Burrell of Delavan, Wis. Usingammonia as the cooling medium, the swept surface heat exchanger wasoperated to crystalize the fat in the water-in-fat dispersion totransform the water-in-fat dispersion into a water-in-fat matrix andsubsequently work the water-in-fat matrix. The composition of the butterfeed and the composition of the product produced in this example, alongwith details about component removal and component addition, arepresented in Table 3 below.

The water removal number of 219 pounds (about 99.3 kilograms) in Table 3does not reflect the actual measured amount of water removed from thebutter for at least a couple of reasons. First, about 133 extra pounds(about 60.3 kilograms) of water were inadvertently added to the meltedbutter during processing through the evaporator. It is believed that thewater was either added to the melted butter during transfer of themelted butter to the evaporator or in the evaporator itself Secondly,some of the materials being transferred from the mix tank to theexchanger were left in the transfer line after processing was completein the exchanger. This loss of water during exchanger processing and thegain of water proximate the evaporator are believed to be reflected inthe 219 pounds (about 99.3 kilograms) of water removal that is shown inTable 3, versus the observed water removal of about 292 pounds (about132.5 kilograms) to about 300 pounds (about 136 kilograms) in theevaporator.

Additionally, salt removal and solids non-fat removal are shown in Table3. This removal of salt and solids non-fat is believed attributable tomaterial remaining in the transfer line from the mix tank to theexchanger following production of the butter/margarine blend in theexchanger. Similarly, the fat removal number of 1,398 pounds (about 634kilograms) in Table 3 is larger than the observed removal of about 1,200pounds (about 544 kilograms) to about 1,250 pounds (about 567 kilograms)of butterfat. This difference in butterfat removal is likewise believedattributable to line losses similar to the noted line loss of salt andsolids non-fat.

TABLE 3 Pounds of Components Added Feed Butter To Butter ProductComposition Component Solids Intermediate Composition Pounds RemovalPounds Pounds Ingredient Component Wt % (kg) (kg) Ingredient (kg)Component Wt % (kg) Butter Water 14.71 323.6 219 Water 11.09 104.6(˜147) (˜99) (˜47) Butterfat 82.96 1825 1398 Butterfat 427 Butterfat45.29 427 (˜828) (˜634) (˜194) (˜194) Salt 0.88 19.4 3.7 Salt 1.67 15.7(˜8) (˜2) (˜7) SNF** 1.45 32 SNF** 2.18 20.6 (˜14) (˜9) Oil*** 131Oil*** 13.89 131 (˜60) (˜60) Oil**** 244 Oil**** 25.88 244 (˜111) (˜111)TOTAL 100.00 2200 1620.7 TOTAL 802 TOTAL 100.00 942.9 (˜998) (˜735)(˜364) (˜428) *Includes approximately 133 pounds (about 60.3 kilograms)of process water that was inadvertently added to the cream feed duringtransfer of the cream feed to the evaporator **Solids Non-Fat ***liquidsoybean oil ****HM508 oil blend

The butter/margarine blend produced in this example was taste tested bya panel of tasters and was also incorporated into baked goods. The panelof taste testers preferred the butter/margarine blend of this exampleover Grade AA salted butter, because the butter/margarine blend had aricher butter taste than even the Grade AA salted butter. Also, thetaste panel observed that the butter/margarine blend had an improvedmouth-feel even compared to the mouth-feel of Grade AA salted butter.Additionally, it was observed that the butler/margarine blend was easierto spread on bread than Grade AA salted butter that had not beenpresoftened. Finally, when baking using the butter/margarine blend, itwas observed that the butter/margarine blend produced enhanced body inbaked goods, as compared to the body of baked goods that incorporatedGrade AA salted butter, and also increased the uniformity and rate atwhich the baked goods browned, as compared to baked goods incorporatingGrade AA butter.

Comparative Example No. 1

In this comparative example, an attempt was made to produce margarine bystarting with cream containing 40 weight percent milk fat, based uponthe starting weight of the cream, instead of starting with churnedbutter, to create a margarine In Table 4 below, the pounds of watershown for the cream feed (40 wt % fat) is about 400 pounds (about 181.4kilograms) greater than for the cream feed alone because approximately400 pounds (about 181.4 kilograms) of process water was inadvertentlyadded to the cream feed during transfer of the cream feed to theevaporator.

The cream was fed to a falling film evaporator, similar to the fallingfilm evaporator used in Example 3, that is available from MarriottWalker Corporation of Birmingham, Mich. Vacuum on this falling filmevaporator was provided by a thermal compressor that is available fromCroll-Reynolds Company of Westfield, N.J. The cream was introduced intothe evaporator at a temperature of about 136° F. (about 57.8° C.). Afterwater was removed in the evaporator, the reduced moisture cream wasplaced in a mix tank and combined with some hydrogenated soybean oil andsome liquid soybean oil, along with some salt.

Thereafter, the mixture of reduced moisture cream and soybean oil wasblended using an agitator in the mix tank to form a homogeneouswater-in-fat/oil dispersion. The water-in-fat/oil dispersion was thentransferred to a crystalizing exchanger. In this comparative example,the crystalizing exchanger was a Votator® 672DE swept surface heatexchanger available from Waukesha Cheny-Burrell. The water-in-fat/oildispersion was processed through the swept surface heat exchanger to anoutlet temperature of about 58° F. (about 14.4° C.).

The composition of the cream used as feed in this comparative example,and the product composition, along with component removal and additiondetails, are presented in Table 4 below. The intended amount of waterremoval in this comparative example was less than the actual amount ofwater removal that is shown in Table 4 as being removed. Approximately400 pounds (about 181.4 kilograms) of extra water was removed in theevaporator to compensate for the approximately 400 pounds (about 181.4kilograms) of process water that was inadvertently added to the creamfeed to the evaporator. Also, some unintended butterfat removal, alongwith some unintended water removal, occurred as a result of line lossesbetween the mix tank and the crystalizing exchanger. Furthermore, somesolids non-fat removal likewise occurred due to line losses in the lineconnecting the mix tank and the crystalizing exchanger.

TABLE 4 Components Added To Feed Pounds of The Concentrated ProductComposition Component Cream Feed Composition Pounds Removal PoundsPounds Ingredient Component Wt % (kg) (kg) Ingredient (kg) Component Wt% (kg) Cream* Water 67.98 964* 853.2 Water 12.80 110.8 (˜436) (˜296)(˜50) Butterfat 28.21 400 52 Butterfat 0 Butterfat 40.19 348 (˜181)(˜24) (0) (˜158) Salt 0.00 0 Salt 13.4 Salt 1.55 13.4 (0) (˜6) (˜6)SNF** 3.81 54 SNF** 5.28 45.7 (˜24) (˜21) Oil*** 226 Oil*** 26.10 226(˜102) (˜102) Oil**** 122 Oil**** 14.08 122 (˜55) (˜55) TOTAL 100.001418 TOTAL 361.4 TOTAL 100.00 865.9 (˜643) (˜163) (˜392) *Includesapproximately 400 pounds (about 181.4 kilograms) of process water thatwas inadvertently added to the cream feed during transfer of the creamfeed to the evaporator **Solids Non-Fat ***hydrogenated soybean oil****liquid soybean oil

This comparative example yielded two striking observations. First,during processing of the cream in the evaporator, it was observed thatsignificant fouling and clogging occurred in the evaporator. This isbelieved to be a result of the aqueous phase of the cream containing anexcessive amount of solids as evaporation of water proceeded, since amuch larger percentage of incoming water must be evaporated from creamcontaining 40 weight percent fat, as compared to the amount of water tobe evaporated from butter, to achieve a similar fat/water ratio in thecompleted product.

Furthermore, the initial concentration of solids in cream containing 40weight percent fat is significantly higher than the concentration ofcomparable solids in butter, since churning of cream to form butterremoves, in the butter milk product of the churning process, asignificant amount of solids from the incoming cream being churned. Theevaporator clogging problem significantly reduced the flow rate of creamthrough the evaporator as fouling and clogging increased in theevaporator during the run. Nonetheless, some flow of reduced water creamthrough the evaporator did continue so that margarine was ultimatelyable to be formed in the crystallizing exchanger.

When provided to a taste panel, the tasters found that the margarineproduced in this comparative example had a flavor that was notacceptable. Specifically, the flavor of the margarine, as compared tothe flavor of butter, was merely milky, had a greatly diminished fattytaste or mouth-feel, and virtually no butter flavor, as compared tobutter. Thus, this comparative example demonstrates that it is notfeasible or acceptable to use cream that has not been churned intobutter, as a substitute for butter, in or as the feed material 12 of thepresent invention.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

What is claimed is:
 1. A method of forming a butter-based product, themethod comprising: removing water or butterfat from a feed material toyield an intermediate, the feed material comprising butter; combining anon-dairy fat with the intermediate to form an intermediate blend; andprocessing the intermediate blend to form the butter-based product. 2.The method of claim 1, the method further comprising combining butterfatwith the non-dairy fat and the intermediate to form the intermediateblend.
 3. The method of claim 1 wherein processing the intermediateblend comprises transforming the intermediate blend into a water-in-fatdispersion.
 4. The method of claim 1 wherein the feed material comprisesinterfacial butter solids and the intermediate comprises interfacialbutter solids, at least about 95 weight percent of the interfacialbutter solids of the feed material, based on the total weight of theinterfacial butter solids in the feed material, being present in theintermediate.
 5. The method of claim 1 wherein: the feed materialcomprises an interfacial butter solids portion; the interfacial buttersolids portion consist of phospholipids, proteins, and sugars; and atleast about 95 weight percent of the interfacial butter solids portion,based on the total weight of the interfacial butter solids portion inthe feed material, being present in the intermediate.
 6. The method ofclaim 1 wherein removing water or butterfat from the feed materialcomprises removing water or butterfat from the butter.
 7. The method ofclaim 6, the method further comprising heating the feed material to meltthe butter and form melted butter, and wherein removing water orbutterfat from the butter comprises removing water or butterfat from themelted butter.
 8. The method of claim 1 wherein removing water from thefeed material comprises evaporating water from the feed material.
 9. Themethod of claim 1 wherein removing water from the feed materialcomprises freeze drying the feed material or spray drying the feedmaterial.
 10. The method of claim 1 wherein the non-dairy fat isselected from the group consisting of animal fat, plant fat, and any ofthese in any combination.
 11. The method of claim 1 wherein the buttercomprises interfacial butter solids, the concentration of interfacialbutter solids being higher in the butter-based product than theconcentration of interfacial butter solids in the butter.
 12. The methodof claim 1 wherein the butter comprises interfacial butter solids, theconcentration of interfacial butter solids being higher in thebutter-based product than the concentration of interfacial butter solidsin the feed material.
 13. The method of claim 1 wherein: the buttercomprises a fist interfacial butter solids portion; the firstinterfacial butter solids portion consists of phospholipids, proteins,and sugars; the butter-based product comprises a second interfacialbutter solids portion; the second interfacial butter solids portionconsists of phospholipids, proteins, and sugars; and the concentrationof the second interfacial butter solids portion in the butter-basedproduct, based upon the total weight of the butter-based product, ishigher than the concentration of the first interfacial butter solidsportion in the butter, based upon the total weight of the butter. 14.The method of claim 1 wherein: the feed material comprises a firstinterfacial butter solids portion; the first interfacial butter solidsportion consists of phospholipids, proteins, and sugars; thebutter-based product comprises a second interfacial butter solidsportion; the second interfacial butter solids portion consists ofphospholipids, proteins, and sugars; and the concentration of the secondinterfacial butter solids portion in the butter-based product, basedupon the total weight of the butter-based product, is higher than theconcentration of the first interfacial butter solids portion in the feedmaterial, based upon the total weight of the feed material.
 15. A methodof processing butter, the butter comprising interfacial butter solids,the method comprising: melting the butter; and removing water orbutterfat from the melted butter, to form a concentrated butter product,the concentrated butter product comprising: butterfat; and substantiallyall of the interfacial butter solids present in the butter.
 16. Themethod of claim 15 wherein the concentration of interfacial buttersolids is higher in the concentrated butter product than theconcentration of interfacial butter solids in the butter.
 17. The methodof claim 15, the method further comprising combining a non-dairy fatwith the concentrated butter product.
 18. A method of forming abutter-based product, the method comprising: removing water or butterfatfrom a feed material to yield an intermediate, the feed materialcomprising butter and non-dairy fat and the intermediate comprisingwater, butterfat, and non-dairy fat; crystallizing butterfat in theintermediate to form the butter-based product.
 19. The method of claim18 wherein the butter comprises interfacial butter solids, theconcentration of interfacial butter solids being higher in thebutter-based product than the concentration of interracial butter solidsin the butter.
 20. A method of forming a butter-based product, themethod comprising: removing water from a feed material to yield a firstintermediate, the feed material comprising butter; removing butterfatfrom the first intermediate to yield a second intermediate, the secondintermediate comprising butterfat and interfacial butter solids; andcrystallizing butterfat that is present in the second intermediate toform the butter-based product.
 21. The method of claim 20 wherein thebutter comprises interfacial butter solids, the concentration ofinterfacial butter solids in the butter-based product being higher thanthe concentration of interfacial butter solids in the butter.
 22. Themethod of claim 20 wherein the butter comprises interfacial buttersolids, the concentration of interfacial butter solids being higher inthe butter-based product than the concentration of interfacial buttersolids in the feed material.
 23. The method of claim 20 wherein: thebutter comprises a first interfacial butter solids portion; the firstinterfacial butter solids portion consists of phospholipids, proteins,and sugars; the butter-based product comprises a second interfacialbutter solids portion; the second interfacial butter solids portionconsists of phospholipids, proteins, and sugars; and the concentrationof the second interfacial butter solids portion in the butter-basedproduct, based upon the total weight of the butter-based product, ishigher than the concentration of the first interfacial butter solidsportion in the butter, based upon the total weight of the butter. 24.The method of claim 20 wherein: the feed material comprises a firstinterfacial butter solids portion; the first interfacial butter solidsportion consists of phospholipids, proteins, and sugars; thebutter-based product comprises a second interfacial butter solidsportion; the second interfacial butter solids portion consists ofphospholipids, proteins, and sugars; and the concentration of the secondinterfacial butter solids portion in the butter-based product, basedupon the total weight of the butter-based product, is higher than theconcentration of the first interfacial butter solids portion in the feedmaterial, based upon the total weight of the feed material.
 25. Themethod of claim 20, the method further comprising adding non-dairy fatto the second intermediate prior to crystallizing butterfat.
 26. Themethod of claim 20, the method further comprising adding butterfat tothe second intermediate prior to crystallizing butterfat.
 27. The methodof claim 20 wherein the feed material comprises interfacial buttersolids, at least about 95 weight percent of the interfacial buttersolids of the feed material, based on the total weight of theinterfacial butter solids in the feed material, being present in thesecond intermediate.
 28. The method of claim 20 wherein: the feedmaterial comprises an interfacial butter solids portion; the interfacialbutter solids portion consist of phospholipids, proteins, and sugars;and at least about 95 weight percent of the interfacial butter solidsportion, based on the total weight of the interfacial butter solidsportion in the feed material, being present in the intermediate.
 29. Abutter-based product derived from butter wherein the butter comprisesinterfacial butter solids, the butter-based product comprising:butterfat; water; a non-dairy fat; and interfacial butter solids, theconcentration of interfacial butter solids being higher in thebutter-based product than the concentration of interfacial butter solidsin the butter.
 30. The butter-based product of claim 29 wherein thebutter comprises water and butterfat, the weight ratio of butterfat towater in the butter-based product being different from the weight ratioof butterfat to water in the butter.
 31. The butter-based product ofclaim 29 wherein the non-dairy fat is selected from the group consistingof animal fat, plant fat, and any of these in any combination.
 32. Thebutter-based product of claim 29 wherein: the butter comprises a firstinterfacial butter solids portion; the first interfacial butter solidsportion consists of phospholipids, proteins, and sugars; thebutter-based product comprises a second interfacial butter solidsportion; the second interfacial butter solids portion consists ofphospholipids, proteins, and sugars; and the concentration of the secondinterfacial butter solids portion in the butter-based product, basedupon the total weight of the butter-based product, is higher than theconcentration of the first interfacial butter solids portion in thebutter, based upon the total weight of the butter.
 33. A concentratedbutter product, the concentrated butter product derived from butter, thebutter comprising interfacial butter solids, the concentrated butterproduct comprising: water; butterfat; and interfacial butter solids, theconcentration of interfacial butter solids in the concentrated butterproduct being greater than the concentration of the interfacial buttersolids in the butter.
 34. The concentrated butter product of claim 33wherein the butter further comprises water and butterfat, the weightratio of butterfat to water in the concentrated butter product beingdifferent from the weight ratio of butterfat to water in the butter. 35.The concentrated butter product of claim 33 wherein: the buttercomprises a first interfacial butter solids portion; the firstinterfacial butter solids portion consists of phospholipids, proteins,and sugars; the concentrated butter product comprises a secondinterfacial butter solids portion; the second interfacial butter solidsportion consists of phospholipids, proteins, and sugars; and theconcentration of the second interfacial butter solids portion in theconcentrated butter product, based upon the total weight of theconcentrated butter product, is higher than the concentration of thefirst interfacial butter solids portion in the butter, based upon thetotal weight of the butter.
 36. A butter-based product, the butter-basedproduct derived from butter, the butter comprising water, butterfat, andinterfacial butter solids, the butter product comprising: interfacialbutter solids; butterfat; and water, the weight ratio of butterfat towater in the butter product being larger than the weight ratio ofbutterfat to water in the butter.
 37. The butter-based product of claim36 wherein the concentration of interfacial butter solids in thebutter-based product is higher than the concentration of interfacialbutter solids in the butter.
 38. The butter-based product of claim 36wherein: the butter comprises a first interfacial butter solids portion;the first interfacial butter solids portion consists of phospholipids,proteins, and sugars; the butter-based product comprises a secondinterfacial butter solids portion; the second interfacial butter solidsportion consists of phospholipids, proteins, and sugars; and theconcentration of the second interfacial butter solids portion in thebutter-based product, based upon the total weight of the butter-basedproduct, is higher than the concentration of the first interfacialbutter solids portion in the butter, based upon the total weight of thebutter.
 39. The butter-based product of claim 36, the butter-basedproduct further comprising non-dairy fat.